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Control System Security and Access Operator Interfaces and the Mobile Workforce PLC vs DCS Fieldbus, Ethernet & Wireless Energy & Emissions Management Safety: Lifecycle and Procedural Automation Approaches Start-Ups, Upgrades & Migrations
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CONTENTS
Sponsored by:
4 Contributors 7 Introduction 8
11 PLC vs. DCS: Which is Right for Your Operation? 14 PLC Lifecycle Management 17 Operator Interface Trends 20 How Reusable Code Streamlines Recipe Management 24 Are Intelligent Instruments The Right Choice? 28 Managing Emissions with Automation 31 How to Conduct an Energy Audit 36 Energy Management Best Practices 41 The Impact of Variable Speed Drives 44 Safety: The Lifecycle Approach 49 Procedural Automation for Greater Safety and Productivity
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CONTENTS
66 Wireless Trends 69 Wireless Sensor Applications
52 Four IT Standards You Should Understand 55 Fieldbus & Ethernet in Continuous Process Applications 59 Understanding the Differences Among Industrial Ethernet Protocols
71 Wireless Protocols for the Process Industries 73 How to Avoid Mistakes with Control System Remote Access 77 Control System Security Tips 80 Leveraging Analytics and Community for a Mobile Workforce 84 Automation as a Continuous Improvement Tool for Everyone 89 Combining OEE and Automation for Improved Performance 92 Four Considerations for Upgrades & Migrations 95 VENDOR SELECTION RESOURCE GUIDE
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CONTRIBUTORS
Brooke Robertson
Project Manager Regional Control Specialist, EPCD Momentive Specialty Chemicals Inc.
Michael Thibodeaux
Industrial Automated Systems Security Engineer BASF
Joe Staples
Head of Manufacturing Systems North America Bayer CropScience
Dennis Brandl
President BR&L Consulting
Chris Wells
Senior Staff Instrumentation Engineer ExxonMobil Chemical Company
Steven Toteda
Chairman of WINA (Wireless Industrial Networking Alliance)
Dave Woll
Vice President ARC Advisory Group Inc.
Bob Rochelle
Food and Packaging Industry Specialist Staubli Corporation
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CONTRIBUTORS
Cyle Nelson
Senior Software Architect Adept Technology
Chris Bacon
Operations Productivity Analyst ISS Productivity
Carl Henning
Profinet
Scott Hibbard
Sercos III
Shaun Kneller
Ethernet Powerlink
Chuck Lukasik
CC Link IE
Joey Stubbs
EtherCAT
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CONTRIBUTORS
Control System Integrators Association (CSIA)
Automation World worked with CSIA to gain access to the expertise of its system integrator members to bring you much of the content in this playbook. To become a member of CSIA, a control system integration firm must demonstrate experience and commitment to the field. Members who earn CSIA Certification have passed an independent audit of 80 criteria covering all aspects of business performance, including general management, financial management, project management, quality management, supporting systems, human resources and more. To maintain their certification, CSIA Certified members must be re-audited every three years. For more information about CSIA and its system integrator members, visit http://www.controlsys.org
Chetan Chothani
President Adaptive Resources
Antonio Manalo
Automation Systems Integrator Avid Solutions
Alex Palmer
Team Lead Aseco Integrated Systems
Dario Rossi
Chief Engineer Aseco Integrated Systems
Robert Snow
Senior Process Control Engineer Optimation
Russel Treat
President-CEO Enersys Corp
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INTRODUCTION
Director of Media & Events for Automation World
By David Greenfield
Automation may not be such a big word when it comes to letter count, but when it comes to meaning and concept its a doozy. The term automation encompasses everything from controls, sensors, networks and interfaces to motors, drives, actuators and software. When youre deeply involved with the production operations typically conducted by facilities dealing with chemicals, metals, mining, or oil & gas, all the potential automation applications that must also be considered can boggle the mind. Knowing how confusing all these technological options can be, Automation World has developed this continuous processing-focused playbook to provide a resource on some of the most basic automation issues encountered in the industry. Using this playbook as a helpful resource, youll have a handy, quick-read reference on topics ranging from fieldbus and industrial Ethernet basics, operator interface trends, and control system security to project start-up concerns, system migration issues, and variable speed drive considerations. We hope youll find this continuous process playbook to be a useful source of information now and in the years ahead as you plan for new projects or upgrade existing production functions.
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By Marty Weil
Project development is not an everyday occurrence at continuous process facilities. To help ensure you are covering all the major issues involved in these infrequent work scenarios, here are some tips and considerations to facilitate a successful project startup.
David Greenfield
1. Clearly identify the project specifications. What do you want to do? What is
your existing process? Define operator involvement, quality control issues, interface points with other systems, and the technological capability available in-house.
2. Conduct a job risk assessment (JRA). Performing a JRA before the start of work
highlights any hazards that could produce undesirable results to personnel or property. A safety assessment must be completed to ensure that the scheduled work can be performed in a safe manner and to address any hazards that are uncovered as a part of the review process.
3. Operator training is key. The operators must learn how to navigate and operate
their process in the new control system. The training must be performed just in time (about two weeks before start-up) so that the information is fresh in their minds. During the instruction, it is critical that the operators be trained using the operator interface graphics they will encounter.
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operations departments is critical to the success of the project. Maintenance and Operations need to schedule their duties with enough lead-time to support the installation and start-up activities. With enough time, maintenance can even contract back-fill support for the duration of the project start-up activities. For operations, the work and vacancy relief schedule will have to be organized so that enough operators are available to cut-over and start-up the plant. This is especially important if a hot cut-over is involved.
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Over the past decade, the functionality of different control systems has been merging. Programmable logic controllers (PLCs) now have capabilities once found only in distributed control systems (DCSs), while a DCS can handle many functions previously thought more appropriate for PLCs. So whats the difference between the two control approaches, wheres the dividing line and are there still reasons to choose one over the other? PLCs grew up as replacements for multiple relays and are used primarily for controlling discrete manufacturing processes and standalone equipment. If integration with other equipment is required, the user or his system integrator typically has to do it, connecting human-machine interfaces (HMIs) and other control devices as needed. The DCS, on the other hand, was developed to replace PID controllers and is found most often in batch and continuous production processes, especially those that require advanced control measures. The vendor handles system integration, and HMIs are integral. As users demanded more production information, PLCs gained processing power and networking became common. PLC-based control systems began to function like a miniDCS. At the same time, the DCS hybridized to incorporate PLCs and PCs to control certain
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functions and to provide reporting services. The DCS supervises the entire process, much like the conductor in an orchestra. Protocols, like OPC, have eased interactions between the two control systems. Since PLCs are less expensive and can now perform much like a DCS, wouldnt it make sense to convert everything to PLCs? The answer, like most things in the world of automation, is that it depends on the needs of your application. Here are six key factors to consider:
1. Response time
PLCs are fast, no doubt about it. Response times of one-tenth of a second make the PLC an ideal controller for near real-time actions such as a safety shutdown or firing control. A DCS takes much longer to process data, so its not the right solution when response times are critical. In fact, safety systems require a separate controller.
2. Scalability
A PLC can only handle a few thousand I/O points or less. Its just not as scalable as a DCS, which can handle many thousands of I/O points and more easily accommodate new equipment, process enhancements and data integration. If you require advanced process control, and have a large facility or a process thats spread out over a wide geographic area with thousands of I/O points, a DCS makes more sense.
3. Redundancy
Another problem with PLCs is redundancy. If you need power or fault tolerant I/O, dont try to force those requirements into a PLC-based control system. Youll just end up raising the costs to equal or exceed those of a DCS.
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4. Complexity
The complex nature of many continuous production processes, such as oil and gas, water treatment and chemical processing, continue to require the advanced process control capabilities of the DCS. Others, such as pulp and paper, are trending toward PLC-based control.
6. Vendor support
DCS vendors typically require users to employ them to provide integration services and implement process changes. System integrators perform similar functions for PLC-based systems. It has also become common for PLC vendors to offer support services through their network of system integrator partners. Process control has become increasing complex. Its difficult for any individual to know everything about these sophisticated systems, increasing the need for vendor support. Manufacturers also continue to reduce factory staff and a generation of experienced process control personnel has begun to retire. As a result, the quality of support has become a critical factor in vendor selection.
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By David Greenfield
Discussion of controllers in the continuous process industries typically centers on distributed control systems (DCSs). However, programmable logic controllers (PLCs) play as important a role in the process industries as they do in discrete manufacturing, particularly when it comes to operations reliability and protection of personnel. Some of the more significant applications for PLCs in the process industries include control of safety-instrumented systems and control of major machinery. Like many discrete manufacturing operations, most process operations use a variety of PLCs from different vendors. As a result, your ability to effectively operate and manage these disparate PLC versions has a direct impact on your plant reliability and safety. Following is a list of the top three PLC lifecycle management concerns for the process industries and how some of your peers are working with PLC suppliers to address those issues, compiled from presentations delivered at The Automation Conference 2012.
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are asking of their PLC vendors to help them better manage their PLC assets over the long, continuous operation periods common to the process industries.
1. Life extension. Because of the long periods of time that typically pass between
maintenance shutdowns in process facilities, users need to be able to source and use components for longer-than-expected lives. Many facilities in the continuous process industries are still looking at 20 to 30 years as a life cycle for their equipment. Talk to your vendor about their ability to support backwards compatibility with new components as they become available over these long lifecycles. These new components should be able to be integrated into your system without requiring a shutdown for upgrading.
2. Online upgrades. More vendors are coming around to this request of process
industry end users, as it is often the easiest way to upgrade a PLCs logic without shutting it down or rewiring the I/O. One process industry end user told us: If you look at the total cost of an upgrade, the cost of the hardware is dwarfed by the cost of labor to re-do things like I/O rewiring and the cost of the unit shutdown. Therefore, online version upgrades that can be installed while the PLC is running and that work with the existing I/O is ideal.
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By Marty Weil
David Greenfield
Operator interaction with production machinery is critical from both a standard operations aspect as well as for analytical and safety reasons. Following are some of the most significant recent developments in operator interface (OI)/human machine interface (HMI) technologies for the process industries:
Improved graphics provide detailed context for machine data, enable faster analysis, and facilitate better and more rapid understanding of information. Operators are presented the right information, in the right format, at the right time. This empowers them to make timely, informed decisions and to take immediate actions to reduce costs and operational incidents, improving productivity across the total operation.
Training
The higher level of functionality and interaction embedded in todays HMI better reflects the essential experience of a machine or process. This is ideal for training, and speeding time-tocompetency among operators. The value provided by HMI in the training arena is reflected in ease-of-use, higher efficiency and productivity, reduced time to complete tasks, improved user satisfaction, greater trust in systems, and fewer user errors.
Workforce Demographics
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Over the next decade, process industries face the challenge of replacing an aging workforce with an Internet-driven, computer-savvy, video-gaming generation of employees. Industries
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must preserve, maintain, extend, and institutionalize their workforce knowledge efficiently and effectively to sustain operational excellence. Improved HMI technology, including HMI with virtual reality techniques, is helping in this critical effort, providing an effective means to train the new workforce in ways that dovetail with their generational interests and native skills.
Virtual Reality
Though virtual reality techniques are primarily being used for new user training applications related to basic equipment operations, they can also be used to expose personnel to simulated hazardous situations in a safe, highly visual, and personally interactive way. Customized simulations of plant layouts, dynamic process operations, and comprehensive virtual environments can be set up to allow users to move within the virtual plants, make operational decisions, and investigate processes at a glance. Trainees see the consequences of correct and incorrect decisions immediately, providing the opportunity to directly learn from their successes and mistakes.
As you explore available HMI technologies, ask yourself: Is it easy to exchange essential information from this HMI with different systems or controllers? Is the application code locked for customization of objects or functions? Will runtime software be able to operate on different hardware platforms? These are the kinds of questions being discussed between HMI vendors and their customers, and increasingly the right answers to these questions depends on the HMIs use of open platform architectures. As HMI products evolve in their use of these platforms, HMIs will be less proprietary and more open, offering greater freedom to the user in terms of choice of runtime platforms.
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Think automation is just another business cost? Think automation is tactical and not strategic? Think no one has enough of the right resources to execute your automation work?
Among the issues facing HMI developers are userconstrained environments, collaborative work functions, and facilities for individuals with restricted mobility. These challenges have led to a number of HMI innovations, including:
abstract specification of required user interactions independent of operation modes or device implementations;
in noisy environments without the use of special training or requiring a specific speech recognition start trigger.
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Looking for a way to implement a flexible production strategy without breaking your budget or spending weeks or months writing new software code? The answer can be found in ANSI/ ISA-88.00.03-2003, a control industry standard that establishes best practices for automating batch manufacturing plants and batch control. Although originally designed for batch manufacturing processes, the ISA-88 standard is also helping users save time and money in automating continuous production processes.
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The next two levels, process cell and unit, are the building blocks of the production process. One or more units are contained in each process cell. Each unit is a collection of controlled equipment. Within the unit are the equipment and control modules. An equipment module defines a small group of equipment with a process function and can contain control modules and subsidiary equipment modules. The control module contains the equipment and systems that perform the actual process control.
Universal Structure
The standard can be applied to either simple or complex processes, so that one programming system can be used for all production processes in a plant. Using this methodology, users and programmers can:
Identify the structure and format for recipes and procedures; Define levels of recipes and procedures; Recognize product-specific recipes and procedures that are separate from processoriented equipment and its direct control;
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Broad Applicability
Industry experts say an estimated 50 percent of all U.S. manufacturing is now accomplished using techniques and technologies consistent with the ISA-88 standard, which has been proven in thousands of applications and can be applied in either DCS or PLC control environments.
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Reduce a user's time to reach full production levels Enable vendors to supply appropriate tools for Enable users to better identify their needs; Make recipe development straightforward enough
Reduce the cost of automating batch processes; and Reduce life-cycle engineering efforts.
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The process industries are increasing use of intelligent instruments that provide operators and plant managers with a broader range of operational information than their analog predecessors. Now that these instruments have been available for years, its apparent that the difference in application success with them often hinges on whether or not the company using them is prepared to take advantage of the benefits they offer.
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Intelligent instrument capabilities and vendor offerings vary widely. As a result, one of the biggest challenges to gaining all the benefits offered by intelligent instruments has been the lack of uniform methods for accessing information. To overcome this, the control industry has begun setting standards such as Field Device Tool, or FDT, making it easier to communicate with and configure different devices from multiple vendors.
Core Benefits
Ethernet networks make it easy to calibrate, configure and adjust process parameters
remotely, similar to how a printer driver works on a computer.
Smart devices can self-address and self-report their status, simplifying remote
troubleshooting and reducing maintenance costs and manpower.
Smart instruments with multiple capabilities reduce the number of devices required, Process data that lets you anticipate failures can improve predictive maintenance,
increasing uptime and reducing waste.
as well as the cost of programming, wiring and installation, lowering the total cost of ownership.
Getting better information faster, can help you improve process efficiency, increase
productivity and actually reduce the cost of innovation.
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Drawbacks
Intelligent instruments are not plug-and-play. While more information can be gathered more accurately, enabling you to adjust processes more quickly, an intelligent control system can also be more complex to manage and maintain. Theres a steep learning curve for intelligent instruments. You have to be realistic. If your control engineering staff isnt willing to move away from centralized decision-making or your maintenance staff has a break-fix mentality, its unlikely theyll be willing to learn how to manage and support the new systems. Intelligent instruments also need to be properly installed. Follow vendor guidelines, install devices correctly, validate your networks and update your cyber security methods. Otherwise, youll be wasting your investment. If this is your first attempt to use intelligent instruments, its best to select the vendor with the broadest offering of applicable devices. Once your team has learned how to manage one vendors instruments, it will be easier to learn anothers.
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In one recent installation, a company invested $5 million in intelligent systems and was able to save $27 million in expensive raw materials used in its production process. Those are the kind of numbers that can attract the attention of the people who control the budgets.
What information is most important to gather for effective decision-making? Too much Do you have industrial networks capable of handling the information flow to and from
smart devices?
information is just noise and can actually be a barrier to making process improvements.
Does your plant follow a proactive program of preventive maintenance? Do the people who manage your control, IT and energy systems talk to each other?
Intelligent control systems cross multiple domains and require integration of people as well as devices.
If your companys production processes are spread out over large areas or involve multiple facilities with similar processes, the benefits from intelligent instruments can be even more significant. Being able to remotely diagnose and fix devices, or replicate process improvements multiple times in multiple locations can deliver big benefits to the bottom line.
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Industries where emissions control is critical include electric utilities, oil and gas, chemical processing, iron and steel, paper, food, mining, metals and cement. But emission control concerns are not limited to these industries. Systems to control and reduce emissions are required for any industrial process that produces sulphur and nitrogen dioxides (popularly referred to as SOx and NOx), the major causes of acid rain, as well as airborne particulates and volatile organic compounds (VOCs). On the horizon are new regulations designed to limit mercury emissions in flue gas. These rules will also apply to industrial facilities, including trash burners and industrial boilers, even if they only generate process steam. More stringent controls on particulates will also require new investments in emissions technologies.
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The list that follows touches upon the primary emission reduction methods used in industry:
Optimized process control is central to reducing NOx emissions from coal-fired power
plants. Oxygen is injected into the boiler to improve combustion and prevent pockets of NOx from being created. A secondary technology, selective non-catalytic reduction, or SNCR, injects urea or ammonia into the boilers, further reducing NOx emissions by up to 20 percent. New low-NOx burners have also been introduced that allow a cooler, more complete burn.
catalytic reduction, or SCR. This capital-intensive technology, which is viable only for large coal-fired plants, involves very large reactors and again injects ammonia into the flow. Automated systems measure NOx levels before and after the reduction process, enabling operators to fine-tune the process.
boilers, injecting air and adjusting dampers to optimize combustion, measure emissions and control heat levels within the boiler to prevent the build-up of slag. By tightening process controls, operators can decrease the amount of raw materials and energy used while reducing waste.
Scrubbers, using either dry or wet processes, use automated systems that regulate
water flows, monitor pH levels and spray lime or apply a slurry of limestone to remove 95 percent or more of sulphur dioxide. A by-product of the scrubber process is calcium sulphate, which is then used to make wallboard.
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At the stack, the air from the process is passed over a rack of sensors that measure
oxygen, carbon dioxide and carbon monoxide levels, as well as sulphur dioxide, sulphur trioxide and nitrogen oxide content.
Most air pollution control devices (APCDs) come as pre-built OEM packages that
include PLC-based automation systems that tend to operate independently of the central DCS system. As new regulations drive greater investment in these APCDs, these systems will need to work together in a more holistic fashion. Achieving this goal will likely require additional automation integration.
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Whether your plant is processing food or chemicals, wastewater or steel, the process used to audit your energy usage and find ways to use or waste less of it is much the same. Before beginning your energy audit process, it is important to realize that, though there are many energy saving steps that result in short-term payback, the average payback time for investments to increase energy efficiency is five years. The older the facility and its equipment, the greater the probability that the energy savings potentialand your return on investment from corrective actionswill be significant.
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Look for steam or compressed air leaks. Are there improperly working natural gas regulators? Does the plant have programmable thermostats? How energy-efficient are the lighting fixtures? Do infrared scans detect any hot spots on the electrical equipment? Also consider the energy efficiency value to be found in straightforward upgrades of existing equipment. For example, have variable frequency drives been installed on motors serving high-energy-consuming equipment, such as cooling towers? Older cooling towers, for example, tend to have motors that run either slow or fast, with none of the gradients that drives can provide to match energy consumption to different operating conditions. Go beyond direct asset-related energy use and ask questions like: Is there lighting thats on when no one is working in a room? Where are the large motor loads, and how and when are they being operated? Are start times being staggered to avoid electrical peak power demand surcharges? Is the plant subjected to extreme seasonal temperature fluctuations between summer and winter?
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Steel plants, for example, are the largest consumers of electrical energy and also incur the most frequent energy spikes because of their use of arc furnaces. The chemical and refining industries, on the other hand, make greater use of compressed air and steam.
Draft a Pre-Plan
Once you have the initial findings from the walkthrough, draw up a pre-plan to address the obvious areas of waste and identify the processes that consume the most energy. Most older plants are poorly metered. If the only meter in the facility is the one measuring the main utility feed, then it will be impossible to determine which machines or processes are contributing the most to your utility bill. The pre-plan should identify where meters are to be located to divide and measure energy use among different processes. The information gathered from these sub-meters can then be used to justify capital expenditures and enable you to develop a longer-term plan based on where the best savings are for the least amount of investment. Most importantly, make sure this plan focuses on the processes used to create the products that contribute the most to the companys productivity and profitability. It should also define a program of preventive maintenance to maintain energy-efficient production processes and allow you to continue to innovate in the future.
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Corrective Actions
Companies are taking many corrective steps to increase their energy efficiency. Among the most common:
Install variable speed drives to match power output with process requirements. Take advantage of the software controlling motors to regulate equipment start-up
times and prevent unscheduled starts.
Install the most energy-efficient light bulbs and other lighting fixtures. Apply automatic lighting controls that turn off lights when rooms are unoccupied. Use programmable thermostats to match temperatures within the plant to operating
requirements.
Eliminate leaks in compressed air and steam systems. Update capacitor banks to maintain correct power factors when new equipment is
installed.
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Changing our attitudes about energy consumption can change our behaviors and lead
to energy savings. There are also more significant capital investments that can be made depending on conditions at your facility. With electricity rates high and natural gas rates currently low, it may make sense to invest in gas-powered turbines. Justifying that kind of investment, however, requires an analysis of the predictability of rates going forward. Further efficiency can be captured with a co-generation system to produce steam as well as electricity, or even tri-generation if your processes require hot water. Another possibility is heat recovery. Investment in piping and heat exchange equipment can allow energy to be passed from one process stream to another, reducing the load on utility sources such as steam and cooling water. How much you can expect to reduce your energy costs will vary from industry to industry and plant to plant. No matter the savings potential at your facility, an energy audit is the first step toward achieving your energy efficiency goals.
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The path to achieving energy efficiency is shaped as much by attitudes and organizational skills as by the physical aspects of reducing energy demands. But its goals can never be achieved without the automation technologies that make it possible to mine information and control the operation of machines. A 2009 study by the Aberdeen Group, a research and consulting firm, found that industry leaders seeking to reduce energy consumption at their facilities viewed energy management as strategic to their business success. The primary tools they applied in their endeavors included advanced visualization, information collection and consumption monitoring. Among the best practices adopted by industry leaders in reducing energy consumption and costs, according to the study, are:
Making energy usage data available to decision-makers in real time. The faster changes
can be made to equipment operations, the greater the energy savings.
Taking energy costs into account when scheduling production. Peak demand charges
can account for as much as 60 percent of a companys energy bills.
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Tying operational metrics to financial metrics. Its essential to understand how the costs
of energy for production and facilities affect the companys bottom line.
Understand Consumption
From a practical perspective, any energy management initiative must start by gaining an understanding of consumption patterns and cost sources from production processes and facilities. Heres a go-to short list to kick off your initiative:
Analyze energy utility contracts and penalties; Conduct an audit of all equipment and their energy sourceswater, air, gas, electricity
and steam (WAGES);
Acquire and analyze energy consumption and cost data; Establish a consumption baseline; and Identify potential savings.
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Prioritize Opportunities
By first attacking the low-hanging fruit, such as leaks in compressed air and steam systems, lack of energy-efficient lighting and utility penalties for peak demand and reactive power, youll gain some early wins at minimal cost. A next step can include installing sub-meters to identify which production activities contribute the most to your energy bills. Ultimately, prioritization means that you must first establish goals, and then phase in a planned program of corrective actions. Heres an outline to follow as you establish your priorities and ensuing goals:
Fix the basics; Focus on processes and assets that are high consumers of energy; Decide where and what to meter; and Develop a phased corrective plan.
Automate
The bulleted list below highlights the predominant users of energy in an industrial facility for which automated solutions exist. otors. Whether they power production equipment, cooling towers or pumps and M
fans in HVAC systems, motors are the biggest sources of industrial energy usage, as well as waste. Adding variable speed drives will better match energy use to operational requirements.
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starts will help avoid peak demand penalties. Utility incentives for demand response programs can be substantial. Automated controls ensure essential loads keep working while minimizing costs.
lighting controls turn off lights when rooms or production areas are not in use. Match illumination levels to task needs. Install energy-efficient bulbs and lighting fixtures.
VAC systems. Drives, automated air dampers and programmable thermostats H can help limit energy usage correlated to operational needs. ower quality. If your plant is experiencing unexplained power outages and motor P failures, or paying penalties for reactive power, low power factor and harmonics may be the cause. Upgrade capacitor banks or electrical equipment where necessary and install corrective filters to extend equipment life.
nergy management. Using software to track power quality, meter energy use, E and control remote monitoring systems will help you access energy information in an organized fashion that speeds decision-making and lets you know where to take corrective action.
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Measure ROI
Energy management is not a one-time event. To achieve sustained savings requires a proactive program of measurement, monitoring and preventive maintenance to make sure that equipment and systems are working in optimal fashion. Periodically measuring the progress achieved in reducing energy consumption and associated costs savings will build support for continuing improvements. As you go about measuring your progress, keep the following in mind:
Always compare actual consumption to baseline; Measure and report all savings; Update plans and priorities based on what you learn from measurements; Incorporate preventive maintenance as part of the process to reduce downtime and
increase savings potential. The core takeaway of these tips is to realize that having a greater awareness of the cost of energy is the first step in changing attitudes about energy consumption and related behaviors in your facility. Following the best practices described above that have been developed and implemented by other processing companies can favorably impact your companys bottom line.
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By Marty Weil
David Greenfield
Continuous processing facilities are finding increasing utilization for variable speed drives/ variable frequency drives (VSD/VFD) to control the motors on pumps, fans, conveyors, etc. This is due to the reliability and low cost of an AC induction motor, as well as the high performance of AC drives. Even though the up-front cost of an AC drive control unit is greater than that of a DC drive, many factors quickly make up the difference. Conservative data indicate a 17 percent savings as a percentage of total system and installation cost using AC drives. Some end users have experienced up to 30 percent savings. While energy usage savings are the primary factor for VSD utilization as utility costs continue to increase, these savings are further supported by increased flexibility in selection of product feed rates, improved accuracy for dispensing of materials, and an increase in access to secondary process performance due to greater access to VSD parameters via control networks. Maintenance can become an issue if there is minimal to no in-house experience with VSDs, however. But most of these concerns can be eliminated with comprehensive training of the maintenance staff prior to project implementation, and reinforced by using the maintenance staff during commissioning.
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of the dynamic reset limit option for the loops in the control system can automatically prevent the process controller from outrunning the response of any type of final element. For best performance, users should consider the following during the specification and implementation of variable speed drive systems:
High-resolution input cards; Pump head well above static head on-off valves for isolation; XPLE (cross-linked polyethylene) jacketed foil/braided or armored shielded cables; Separate trays for instrumentation and VSD cables; Inverter chokes and isolation transformers; Pulse width modulated inverters; Properly set deadband and velocity limiting in the drive electronics; Drive control strategy to meet range/speed regulation requirements; and Dynamic reset limiting using inferential speed or tachometer feedback.
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Vice President ARC Advisory Group and Media and Events Director Automation World
Dave Woll
Production safety is generally thought of as a series of steps necessary to ensure safe interaction with industrial equipment. The process of identifying, agreeing upon and delineating those steps is where things tend to get complicated. Thats why international standards groups play such a significant role, as they set the guidelines for all of industry to follow. For the process industries, IEC 61511 is probably the most widely used safety standard, as it applies to those industries that base their safety systems upon instrumentation. The goal of safety-system design in IEC 61511 is for the process, whatever it may be, to go to a safe state whenever a process parameter exceeds preset limits.
David Greenfield
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IEC 61508 can seem confusing at first, because its underlying philosophy is new for safety standards. Older, more conventional safety standards, stipulated specific rules and specifications for making processes safe. IEC 61508 and its derivative standards, such as IEC 61511, departed from this approach by being more functional, or performance-based. A principal aspect of this new approach to safety standards is that it leverages two fundamental principles: safety lifecycles and probabilistic failure analysis. Unlike previous standards that claimed to cover the entire lifecycle of a project, IEC 61508 and its offshoots actually dofrom project conception to maintenance to decommissioning. In essence, the standards specify safety lifecycle activities that need to be followed over the entire life of a production system. Safety lifecycle management provides a method or procedure that enables companies to specify, design, implement and maintain safety systems to achieve overall safety in a documented and verified manner.
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Perform hazard and risk analysis: Determine hazards and hazardous events, the Allocate safety functions to protection layers: Check the available layers of
protection. Allocate safety functions to protection layers and safety systems.
sequence of events leading to hazardous condition, the associated process risks, the requirements of risk reduction and the safety functions required.
Specify requirements for safety system: If tolerable risk is still out of limit, then
specify the requirements for each safety system and their safety integrity levels.
Design and engineer a safety system: Design system to meet the safety
requirements.
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Design and develop other means of risk reduction: Means of protection other than
programmable safety systems include mechanical systems, process control systems and manual systems.
Install, commission and validate the safety protections: Install and validate that the
safety system meets the all safety requirements to the required safety integrity levels.
Operate and maintain: Ensure that the safety system functions are maintained during
operation and maintenance.
Modify and update: Make corrections, enhancements and adaptations to the safety
system to ensure that the safety requirements are maintained.
decommissioning a safety system. Ensure that the required safety functions remain operational during decommissioning.
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Manage functional safety, safety assessment, and safety audit: Identify the
management activities that are required to ensure that the functional safety objectives are met.
Plan and structure safety lifecycle: Define safety lifecycle in terms of inputs, outputs
and verification activities.
Verify safety system: Demonstrate by review, analysis and/or testing that the required
outputs satisfy the defined requirements for each phase of the safety lifecycle. Activities for Phases I to III are typically carried out consecutively, while Phase IV runs concurrently with the other phases. However, like all models, the safety lifecycle is an approximation.
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Continuous process environments tend to be stable until theyre not. When that happens, the consequences can be catastrophic. Think Deepwater Horizon. The very stability of a continuous production process often induces a false sense of security in operators. Lack of experience with system failure or unexpected alarms can lead operators to freeze when systems suddenly cascade out of control. Procedural automation standards originally developed for batch processes and discrete manufacturing hold promise for helping continuous process operators deal more effectively with sudden emergencies, as well as the more routine changes in state that can occur.
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Imagine a world without electrical standards, such as 110V at 60hz, or 220 at 50Hz, or a world where every phone had a different type of connection and required a different type of switchboard. Just as these standards are critical to the basic functioning of electrical equipment, there are also IT standards used daily to ensure optimal functioning of production systems in the process industries. There are four production-related IT standards of special interest to the processing industries:
The ANSI/ISA 88 standard on batch control; The ANSI/ISA 95 standard for MES and ERP-to-MES communication; The ANSI/ISA 99 technical reports in industrial cyber security; and The new ANSI/ISA 106 technical report on procedure automation.
These standards and technical reports define the best practices for implementing automated and manual control on the systems that reside above the PLC (programmable logic controller) and DCS (distributed control system) level, and which perform the basic control that keep production running. These four standards all share a common view of a production facility,
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By Marty Weil
David Greenfield
In most process industry facilities, the predominant means of communication between field devices and control systems was, for many years, a 4-20 mA analog connection. Though this connection method is highly dependable and still in use, the amount of wiring required is substantial, as each device on the network must have its own separate connection to the controller. As digital technologies emerged on the industrial scene, the capability of fieldbus protocols became a more attractive alternative to analog 4-20 mA communication because of the reduced wiring requirements of fieldbus networks. Less wiring is required with fieldbus because a fieldbus segment can carry both DC power and digital communication signals to numerous separate devices over one fieldbus cable. The predominant fieldbus protocols in the process industries are: Foundation Fieldbus, HART, and Profibus. As Ethernet more clearly becomes the network of choice, not just for the front office, but in production areas as well, the move toward Ethernet-based communications in the process industries is gathering a great deal of attention. Evidence of this can be seen in the increase of end devices for process industry applications that now come standard with an Ethernet
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Originally intended as a replacement for the 4-20 mA standard, Foundation Fieldbus can be found in many heavy process applications such as refining, petrochemicals, and power generation. Two forms of Foundation Fieldbus are available, each uses different physical media and communication speeds: 1 works at 31.25 kbit/s and generally connects to field devices. It provides H
communication and power over standard twisted-pair wiring. Conforming with IEC 61158-2 (as does Profibus, detailed below), power can be delivered over the bus to field instruments, while limiting current flows so that explosive conditions are not created.
subsystems, host systems, linking devices, gateways, and field devices using standard Ethernet cabling. It doesn't currently provide power over the cable, although work is under way to include this feature.
Another significant process industry fieldbus protocol is Profibus PA (process automation), which also operates at 31.25 kbits/s. This protocol is a standard for fieldbus communication in automation technology, first promoted by the German department of education and research (BMBF) and then adopted for use by Siemens. The protocol is commonly found in petrochemical, food/beverage, water and waste treatment plants. Profinet is the open Industrial Ethernet standard from the Profibus/Profinet International group. Profinet uses TCP/IP and IT standards and operates at Ethernet speeds.
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Think automation is just another business cost? Think automation is tactical and not strategic? Think no one has enough of the right resources to execute your automation work?
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By David Greenfield
The rapid adoption of Ethernet on the plant floor over the past decade underscores the need for more production information for better decision-making and the need to simplify networks for easier access and maintenance. But just as there have been wars between the varying fieldbus protocols over the years, a similar posturing over the capabilities of the different protocols persists in the Ethernet arena. To help you make sense of the main differences between six of the major industrial Ethernet protocols, we turn a spotlight on CC-Link IE, EtherCAT, Ethernet/IP, Ethernet Powerlink, Profinet, and Sercos III.
CC-Link IE
CC-Link IE is gigabit speed industrial Ethernet. It is an inherently deterministic network that uses token passing as the mechanism to
guarantee deterministic performance.
No Ethernet switches are required in the basic topology. The protocol is based on ISO model IEEE.802.3 Ethernet at the physical layer.
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CC-Link IE protocol fits at the transport network layer. It is not a TCP/IP or UDP-based
network. This is one of the reasons that its a separate protocol in order to guarantee deterministic operation out of the box.
Frame format of the data is the Ethernet frame. Within the Ethernet frame is a CC-Link
IE frame with header and data information.
EtherCAT
The master does not require a special card to run EtherCAT, and each slave device
or node on the network has an ASIC or FPGA chip inside that implements the entire protocol. The slave doesnt need a micro-controller or random access memory, which means frames can be read and written as data goes through the network at a line speed of 100 Mb/s with no switches built in.
EtherCATs fieldbus memory management unit uses logical addressing so that each
slave device knows where to find its data in the frame, regardless of its physical location. One read-write cycle is capable of talking to all the devices without a great deal of CPU overhead on the controller side.
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EtherCAT supports multiple scan rates and multiple acyclic data exchange rates on the
same network for use in multiple industrial automation processes including motion, I/O, condition monitoring, and data acquisition.
to another protocol to the I/O level. This is due to use of LVDS (low voltage differential signal) a third physical layer in addition to CAT 5 and fiber used to pass the EtherCAT packets directly through all the I/O terminals so that each I/O terminal can be its own independent node on the network.
EtherNet/IP
Safety aspects are addressed through CIP (common industrial protocol) Safety, which
allows safety devices to coexist with standard control devices on the same CIP network, with or without a safety PLC. In this environment, safety sensors can operate alongside
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variable speed drives, safety controllers with standard PLCs and proximity switches. Regardless of the combination of devices used, the integrity of the safety control loop cannot be affected by any of the standard control devices.
combines the requirements of deterministic, real-time, closed loop motion control with standard, unmodified Ethernet, and complies with Ethernet standards, including IEEE 802.3 and TCP/IP. EtherNet/IP with CIP Motion technology enables multi-axis, distributed motion control through application profiles designed to allow position, speed and torque loops to be set within a drive.
Ethernet Powerlink
have to transmit the packet through every single station. When the system transmits back, every node transmits the packet back as a broadcast. This makes it possible to multiplex nodes, which means the node doesnt have to transmit its information back on every single scan, allowing for network optimization and high-speed synchronization.
By using a slot protocol, where each node has a certain slot time on the network and
passes data back to the master in a slot manner, this illuminates any collisions on the system. This gives Ethernet Powerlink fast and predictable cycle times and also allows for the removal and reconnection of nodes to the network without interrupting the cycle.
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Redundancy is built in for ease of network recovery whether using a ring, star or daisy Ethernet Powerlink can be implemented via free download from Sourceforge.net. Its
based on C, so its transportable to controllers or PCs using a standard Ethernet port. With that in place, any system can be connected to a Powerlink network and control Powerlink nodes.
chain topology. If any part of network is disconnected, the system will self recover and report back that the network has gone down.
Profinet uses standard, unmodified Ethernet media, but does not use TCP/IP to
transmit real-time information. When real-time data is being sent, those two layers are skipped. Diagnostic information, however, is accessed over TCP/IP.
Bumpless redundancy meaning that each node sends its message out in both
directions around the ring (when using a ring topology) to ensure at least one message will always get through.
In depth diagnostics are available from the I/O rack level down to a module in that rack. Profinet supports real time I/O for motion control as well as machine-to-machine,
controller-to-controller or peer-to-peer types of communication.
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Profinet allows for integration of other buses (including Foundation Fieldbus, Interbus,
ASI, HART, DeviceNet, and others) via proxies, allowing for maintenance of legacy nodes.
permits a coordinated, centralized shutdown of devices during idle times. This means that individual components or entire subsections of a plant can be switched off automatically when not in use without the aid of external hardware.
PA (the process automation version of Profibus), which can be installed in such an atmosphere and then brought in through a proxy to Profinet.
Sercos III uses a tightly controlled time synchronization signal emitted from a master
control in the system once for every update cycle, providing nanosecond determinism across the network. The time base is a phase-lock loop for deterministic control, allowing for the synchronization of serially connected servo drives, CNCs, and motion controls.
Each message sent from the control contains a master sync telegram for hard real-time
function. This also places fewer burdens on the host processors, freeing them up for tasks such as running control algorithms and machine programs.
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The collective telegram approach underlying Sercos III means that each device places
its input data on common answer telegrams. During the remaining time in the cycle, which for a typical application can be 80 percent or more of the available bandwidth, any standard Ethernet protocol can be transmitted over the network.
Bumpless, single fault redundancy means that Sercos III nodes are specified to detect
broken links in less than 25 microseconds and immediately re-route telegrams back in a double line configuration.
No telegram data is destroyed in a communication cycle over Sercos, thereby allowing
direct cross communication of data between slaves without the CPU burden or time delay that a re-transmission of data by a master would impose.
Sercos III can be integrated with EtherNet/IP, allowing integrators to mix Sercos III,
EtherNet/IP and TCP/IP components within a single machine on a single cable.
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Wireless Trends
Media and Events Director Automation World
By David Greenfield
The history of wireless networking in industry has largely been that of cable replacement. It was simply a tool to deliver communications in places where you simply couldnt run cable for a variety of reasons. Maybe it was too expensive. Or maybe the cable would be running in a hazardous zone. Through these types of applications, wireless secured a foothold in the process industries over the past two decades. Now we are beginning to see a shift in the types of wireless technologies used, as well as different types of applications. This shift is coming from a user-needs perspective, rather than from pure technological capabilities.
2015
19 18 14 22 64
According to the most recent survey from WINA (Wireless Industrial Networking Alliance), the biggest use of wireless technology today is for asset management and condition monitoring. Through the use of wireless sensors that can be positioned nearly anywhere on a piece of equipment, maintenance personnel can get a steady stream of data from that equipment about the state of its condition. The other use of wireless technology, coming in a close second, is incremental process measurements the classic measurements of level, temperature, pressure, and flow. Its not difficult to think of many different places in, say, a refinery or water treatment facility, where it makes sense to get incremental temperature readings from segments of the process where
2011
0%
Source: WINA
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13
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30%
40%
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70%
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you have not been able to collect that data before. Of course, this wouldnt make sense if you had to dig a 1,000-yard trench and stop part of the plant for a couple of weeks while you did Wireless Trends that. But if you could easily put a wireless sensor in that part of the plant and do that very cost effectively, thats effective incremental process measurement. Such small Top Industry Applications For Wireless steps can certainly help you improve your efficiency and, when examined from the aspect of a large process, like a refinery, there are huge overall Asset Management / Condition Monitoring 58% efficiency numbers involved in the end result.
continued
Incremental Process Measurements Mobile Operator / HMI Voice, Video, Data Asset Tracking Control 13% 30% 26%
44%
Wireless sensors are, perhaps, the biggest area for substantial capital expenditure savings in the process industries, especially when you think about the potential benefit of establishing pervasive sensor networks. When you literally start to put hundreds and thousands of devices out in the facility or a refinery, that's when you begin to see real cap-ex savings versus hard wiring. And this has already been documented. For example, using temperature sensors positioned directly on the roller can produce a small percentage of improvement in the surface finish of sheet steel by precisely achieving the proper manifold temperature; this small improvement in quality translates into millions of dollars in savings over the course of the process run. The third most prevalent trend for wireless technology is supporting mobile operators. And its easy to see why: Removing the step of having to connect via an Ethernet jack as measurements are taken at each stop is a big improvement in process.
57%
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Wireless Trends
Following mobile in the fourth and fifth spots are voice/video data communications and asset tracking. These types of wireless applications have been around for years and continue to be deployed due to their successful track record, so its not surprising to see them among the top trends. What is surprising is the application that came in at number six in the 2012 WINA survey control. This is surprising because wireless control had never even ranked in the survey prior to this year. Now, however, 13 percent of survey respondents considered control to be their top application of wireless. In industries like mining, wireless pump control has been around for years, because there is no other way to really do it. But this result indicates that people across industry are beginning to experiment with closed-loop control using wireless.
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By David Greenfield
If youre working in a facility without a great dealor anywireless sensors in place, you may be suspicious about the viability of wireless sensor networks. To help illustrate how ubiquitous wireless sensors have become across industry, following are a few examples of wireless sensor deployments that have become so common that they could be considered textbook application examples. ireless limit switch networks are commonly used to prevent the W
overflow of liquid storage tanks. Their operation is simple: As the tank fills
up, the fluid level forces a change in the position of the limit switch. The wireless limit switch then sends a signal to the pump controller to start pumping out the tank to lower the level. When the fluid level drops to a safe level, the switch then sends a signal to the controller to turn off the pump. he safety and security of oil pipelines is largely handled by T
general manager of the wireless business unit at Cooper Industries and chairman of the Wireless Industrial Networking Alliance (WINA). We're doing a lot of work in Mexico now to monitor and maintain oil pipelines, he says. In these applications, there is a hierarchy of networking tools with sensor networks being used with instrumentation on the pipeline itself to capture data and transmit it back to the control system
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via high-speed backhaul. This combination of technologieswired, wireless and cellularhas really brought wireless to the forefront because youre mixing multiple technologies to monitor pipelines in 20-30 kilometer segments. As you do this with several segments, youre effectively able to monitor hundreds of kilometers of pipelines. major pharmaceutical manufacturer recently decided to A
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Two similar wireless protocolsWirelessHART, promulgated by the HART Communication Foundation (www.hartcomm.org) and ISA 100.11a, promulgated by the International Society of Automation (www.isa.org)are competing for dominance as the enabler of smart instrumentation in Europe and North America. Complicating the issue for end users is the fact that these two standards dont work together. In addition, a third standard, WIA-PA, exists in China and further complicates the task for those with Asian operations. Most process facilities use a mix of wired networks along with their diverse array of instrumentation, but the inability to integrate the two main wireless standards makes that difficult in the wireless realm. Unlike with wired instrumentation, if you want to mix brands of wireless field devices to get an optimum mix of measurements, you cant. You have to have two separate host systems to talk to two different types of field devices. And they have to come from different vendors. In many ways, WirelessHART and ISA 100.11a are alike. They are designed to serve the same market in the same way. At an application level, they perform the same function and have the same benefits. Both ISA 100.11a and WirelessHART implement IEEE 802.15.4 radio hardware. Both protocols use DDL and Device Description files. Both can eliminate a lot of PLC I/O hardware, wiring and associated schematics.
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The principal difference between the two protocols is in the specification of the protocols application layer. WirelessHART, for example, specifies HART as the application layer while ISA100.11a leaves that layer undefined. This means that data in the application layer of ISA100.11a can be transferred using Foundation Fieldbus, Profibus, Modbus, HART or other protocols. While this makes ISA100.11a highly flexible, the customer must decide which protocol to use. WirelessHARTs decision to specify only HART in the application layer was done to deliver simplicity via use of a single data communication specification through the network, meaning that data communication on the network is well-defined and understood. Considering the potential for integrated use of the two wireless protocols, the obstacles preventing a convergence seem to be more commercial than technical. Though the two protocols are similar, investments have been made, vendors and early adopters are lined up on either side, and product certification processes have been established. The two protocols have been developed into products for sale. Marketing programs designed to win over additional customers and vendor partners are in high gear. Both sides believe their approach is right and others should come over to their way of thinking.
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By Marty Weil
David Greenfield
As more operations aspects are tied to Ethernet networks and, therefore, are open to Internetbased access, the potential for greater collaborative operation and a freer work environment increases. But so do the potential for security problems. Following are some basic tips and considerations for achieving secure and reliable remote access:
1. Map out your project from the start. When companies fail to map out their
projects thoroughly from the start, they often find themselves saddled with applications and automation products that dont work cohesively as a single system. Once you start implementing various silosbe they applications or productsthings get more complex. This is typical of problems that occur when automation products are implemented hastily, without doing proper research, planning, or analyzing current and future goals, or without realizing that implementing remote access monitoring for a facility is just step one of many.
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3. Understand users and roles. Understanding users and their roles can have
a significant impact on how the remote access strategy evolves. In most control systems operations, the roles that may require remote access to control assets may include, but are not limited to:
System operators and engineers for local systems; System operators and engineers for remote systems; Vendors; System integrators; System support specialists and maintenance engineers; Field technicians; Business/supply chain partners; Reporting or regulatory entities; and Managed service providers.
The roles of users that would require remote access to mission-critical operations can be extensive and the assignment of specific access depending on those roles can be
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complicated. Map out and document all acceptable access policies and procedures related to allowable network access and coordinate this with industrial control system security experts. Any user access that goes beyond simple viewing of data and permits changes to system parameters should be extremely limited.
4. Know your vulnerabilities. Beginning at the remote user and following the
connection to the data or service, remote access can be compromised at any of the following points:
he user or system can be impersonated to fool the target system. T he attacker can use captured or guessed credentials to impersonate the user. T he attacker can intimidate or coerce the user to provide valid credentials, or to T
perform activities at the attackers demand.
he users access device (laptop, PDA, etc.) can be attacked, compromised, and used to T
access the control system network.
he target system can be impersonated by an attacker to fool the user and thus gain T
credentials or other information from the user system.
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he communication can be interrupted or jammed. T ommunications can have data injected into them by an attacker. C ommunication can be hijacked after it has been initiated (does not rely on C
impersonation) or intercepted during initiation (impersonating both user and target, also known as a man-in-the-middle attack).
n attacker can impersonate a valid communications node and gain access to the A
underlying communications medium.
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By Marty Weil
David Greenfield
Recognizing that the biggest security risk to your control system assets are the operators who interface with the system on a daily basis is the most important step to successfully securing your systems. For a thorough analysis of your risks and setup of reliable control system security technologies and processes, consult an industrial control system security expert such as scadahacker.com, byressecurity.com, or industrialdefender.com. Following are the ground level security steps that a continuous process facility should implement at a bare minimum:
1. Assess your systems. Compile an accurate list of all the assets in your plant: make,
model, and serial number. Where are your computers? Where are your PLCs? Its difficult to secure something when you dont know it exists. This should be a high-level assessment in which you go through your plant and figure out what is high risk and what is low risk, which is determined by two key factors: how likely is a problem to occur? How serious is the problem? For example, if something happened to your chlorine tank, it would be really ugly. That chip pile, not so ugly. Get a feel for the significant risks. Where do you have to focus your effort? The answer is going to drive your decisions and your capital allocation.
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3. Start training. No one is going to follow policies unless they know about them and
understand why they are necessary. All levels of employees that interact with the control system need to understand what an attack looks like and how to respond to one. You should end up with a matrix of training for the various levels of users; it doesn't have to be onerous, but it has to be done.
4. Understand your traffic flows. You need a diagram that shows all the things that
require intercommunication. Smart companies will have a comprehensive diagram showing that the accounting department needs data out of this area, and maintenance needs data out of this area, and so on.
6. Leverage safety reports. Those responsible for safety, when they do reports and
analyses, have done a good deal of the work needed to understand the security risks.
7. Use separate networks. Though this step is becoming less and less practical, some
still advocate that the process control network be kept separate from business networks, and also isolated from the Internet. For this approach, which may not be viable in the longer term, utilize operating system (OS) implemented security, with active directory domain group security as the preferred approach.
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9. Use unique user accounts and passwords. All users should have unique user
accounts and passwords to minimize the risk of unauthorized access.
10. Provide port security. With this approach, the Ethernet MAC address connected
to the switch port allows only that MAC address to communicate on that port. If any other MAC address tries to communicate through the port, port security will disable it. Most of the time, network administrators configure the switch to send an SNMP trap to their network monitoring solution that the ports disabled for security reasons. When using port security, you can prevent unwanted devices from accessing the network.
12. Open and facilitate communications between IT and process control groups. Roles need to be defined and an understanding of what each group
needs must be accomplished so true collaboration can take place to begin and continue the process of enabling a fully functional control system with adequate security protection.
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By David Greenfield
Most businesses in the processing industries have spent the past several years establishing solid technology platforms and infrastructures to gather production data to improve operations. The next step lies in intelligently using those technologies to foster better decision-making, communication, and process improvement. As an example of how this is actually occurring in industry, Joe Staples, head of Manufacturing Systems North America for Bayer CropScience (Kansas City, MO), said that Bayer CropScience has equipped its operators with Invensys Intellitrack mobile devices with workflow software to direct them on how to safely perform the operations required of them. During his presentation at The Automation Conference 2012, Staples said Bayer CropScience is now looking to extend its use of mobile applications so that plant managers, engineers, technicians, and maintenance can get the information they need at any time without have to carry their laptops around or refer to a terminal or a PC. Now the company is looking at extending its use of mobile applications so that plant managers, engineers, technicians, and maintenance can get the information they need at any time without have to carry their laptops around or refer to a terminal or a PC.
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Core to this extension of the mobile workforce at Bayer CropScience is a push for greater employee and operations connectedness through the use of analytics and communities.
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shut the system down or not let it go to the next step until a properly trained engineer or plant manager is there to review and give the go-ahead to move forward.
Community
Bayer CropScience is actively looking at using social media to help in its operations. One of the questions theyre asking is: Why cant the machine participate in a social network? After all, since those devices are now connected, they can provide information via a Facebook page about its health and what its doing. And someone in maintenance at the facility can access that information just as an engineer in another part of the world can. Beyond ubiquitous communication and connectedness, Bayer CropScience is looking to use social networks as a means to leverage its widely scattered technical resources for better collaboration across the globe.
Benefits
These are the benefits Bayer CropScience is already seeing and expects to see more of from its deployment of mobile devices to take advantage of analytics and community: etention and sustainability of knowledge. The company is now R
capturing the expertise of operators and dispersing it so that any operator can become the best operator.
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etter, more rapid focus on issues. By giving operators the information they B need to have, Bayer CropScience is creating a collaborative work environment among all workers no matter where they are located. We can now collaborate on a global basis to deal with issues that arise anywhere, said Staples.
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By David Greenfield
Whether the term used is continuous improvement, Lean, Six Sigma or kaizen, most discussions around these terms focus on how large, world-class companies have achieved these cultural and procedural changes to improve their businesses. Often missing from the discussion is how smaller operations, with far fewer resources, can adopt these practices for significant benefit. Chris Bacon, production manager at Pepsi Bottling Ventures (PBV) in Nampa, ID, described how this small facility (which processes just one-tenth the amount of cases produced at PBVs largest facility), leveraged automation technologies with real-time monitoring controls to bolster a culture of continuous improvement. Though this example originates in the batch process sector, PBVs approach to overall equipment effectiveness (OEE) has lessons for continuous process as well.
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With these data now available, it was decided to disseminate select operational opportunities to all employees and use improvement tools to support the overall goal of maintaining high quality at the lowest cost. Armed with the new data and point-of-contact analysis, line availability and final quality became areas for continuous improvement focus.
Line Availability
The original human machine interface (HMI) screens designed for the mix run filler were cluttered and difficult to decipher. Without in-depth working knowledge of the system, it was easy to lose track of the process flow. By remapping both machine centers in the HMI, the new visuals more accurately captured the physical layout of the systems and improved real-time process flow evaluation. To accomplish this, a simple color code scheme was mapped to relay real-time processes. Green was used for gases, brown for syrup, and blue for water. This simple redesign not only helped during the initial project, but has also allowed for expansion of the
HMI Designs The new HMI visuals, using color-coded schemes, more accurately capture the physical layout of the systems and improved real-time process flow evaluation. Green is used for gases, brown for syrup, and blue for water.
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facilitys trained knowledge base for support growing from one person to eight members of the operation staff across all departments. Furthermore, using Active Factory trending, analysis and reporting software from Wonderware to determine the root cause of a recurring stoppage at both the mixer and the filler, all rinse sequences for the mixer were changed to act only as event triggers (rather than being time- or event-based, as they were in the previous system). This change not only streamlined the programming process, but it eliminated any chance for one trigger sequence starting ahead or at the same time as another, causing the reset status. Another issue was the distribution of water between the filler and mixer during a flavor changeover. In the original programming for the system, the mixer had to complete its rinse before water could be sent to the filler, making it a highly inefficient symbiotic system. With revised programming, both systems perform their end of run functions and rinse sequences simultaneously. Because of these modifications, a reduction of product changeover time from an average of 65 minutes in 2008 to 23 minutes in 2009 was achieved, exceeding PBVs initial 50 percent reduction goal.
Quality
Leveraging OEE calculations for final quality proved to be a major issue, particularly with regard to delivering first-time-through start-ups within specification for the product.
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To achieve this goal, it was necessary to establish a repeatable Brix:TA blend for products at start-up. With scale timers being the most constant factor in the transfer of syrup from the batch room to the mixer, using this measure proved the most logical approach. Once these timers were established to ensure a match with proper product specification, the focus moved to the actual blending of water and syrup within the mixer itself. Because of multiple points in the piping that trapped water, offline testing determined that it was necessary to enrich the syrup higher at start-up to compensate for the water that was impossible to remove. Not wanting to waste more syrup than necessary, testing at multiple points in the piping was performed to test Brix:TA to determine optimum enrichment ratios. From this analysis, it was determined that exceeding OEM Brix set points by 9 percent for the first 70 gallons of syrup, before allowing the recipe to default back to the original set point, was the right approach.
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This calculation was based on analysis and measurement derived from piping length and water left in the system. With these testing methods and trend analysis, first-time-through start-up quality improved nearly 99 percent for all SKUs. Bottom line: This PBV facility went from throwing away as much as 1,800 pieces of production per run to, in most cases, throwing away zero pieces. With an original project start date in late 2008 to design an integrated system for collecting production data, PBV paid for the original project with the yield gains over time reduction based on improved performance by mid 2009; they were also able to produce additional products based on increased line availability.
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By David Greenfield
Overall Equipment Effectiveness (OEE) is a metric designed to evaluate how efficient a production operation truly is based on the real-world availability of the equipment used. Commonly used as a key performance indicator in Lean production efforts, the OEE concept has been around nearly 50 years. It is now starting to gain a stronger foothold in facilities of all sizes due to advances in automation software. Chris Bacon, production manager at Pepsi Bottling Ventures (PBV) in Nampa, ID, described how this small facility (which processes just one-tenth the amount of cases produced at PBVs largest facility), combined the use of automation and OEE tracking as part of its improvement efforts. The key for the Nampa facility was leveraging automation with real-time monitoring controls. Though this PBV example originates in the batch process sector, the approach to OEE and continuous improvement has lessons for continuous process as well. This project began as a way to improve the OEE (overall equipment effectiveness) on the facilitys bottling line, but also became an important bridge towards improving problem solving and developing a continuous improvement culture.
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Results
Armed with this new production insight, one root cause for low performance at the PBV facility was quickly identified the periodic jamming of a vacuum drum on the labeler. PBV realized this problem because of the reason codes now built in to the downtime tracking system.
To learn how Pepsi Bottling Ventures used OEE data to foster a culture of continuous improvement, see Automation as a Continuous Improvement Tool also in this playbook.
With an OEM upgrade to the processor and a few creative internal modifications, PBV was able to reduce downtime by 55 percent at this specific machine center. With this gain in performance, the OEM upgrade was paid off in five months. Long-term results with improved performance also exhibited a 43 percent decrease in labor over time (from 2009 to 2011).
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By Marty Weil
David Greenfield
Regardless of whether you want to increase productivity or shorten time-to-market, attaining success in these areas depends on the application of suitable automation technologies in a continuous process operation. Following are the principal steps involved in assessing your plants technology to gauge whether a technology upgrade or migration is in order:
1. Consider the full range of aspects that relate to your existing systems, such as:
Risk of unplanned plant downtime and production stoppages; Ability to expand production or introduce new products; Ability to integrate with enterprise level business software and at what cost; Ongoing maintenance costs; Need for continuing support of the legacy system; and Effect on the efficiency and productivity of plant personnel.
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2. In each case of upgrade or migration, return on investment plays a crucial role. A huge investment in hardware and application software is associated with
the installed process control system, as well as the accumulated know-how of the operating, engineering, and maintenance personnel. For this reason, the prime objective of any migration strategy should be to modernize the installed base gradually without any system discontinuity and, if possible, without any plant downtimes or loss of production that would negatively affect the investment return.
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for installation? For upgrades, its important to understand what the future outlook is for the system under consideration. With the significant maintenance and security issues tied to process control systems, you should always consider your risk of system obsolescence and the associated costs incurred with such a scenario versus the costs of moving to a better-supported system. The good news is that, in the process industries, most vendors are very aware of the long-term use of their systems by end users and thus tend to support their systems for multiple decades rather a single decade, as is more common with office IT systems. As newer automation technologies become core components of process control systems, be sure to talk with your supplier about their support plan for those newer technologies.
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Cognex
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Cognex
Integrated Lighting and Lens Smarter Tools Faster Image Capture Lighting Power and Control
Unlike most vision systems, the In-Sight 7000 has the capability to power and control specialized lighting directly which eliminates the need for external power supplies.
COMPANY: Cognex
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awgo.to/ecs4
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KeY coMPAnY contAct ECS Solutions, Inc. phone: (812) 479-5170 | Toll Free: (800) 471-ECSE location: Evansville, IN email: Info@ecssolutions.com
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MAVERICK Technologies
Make strategic advances, reduce costs and unlock value across your entire organization DCS migration services through DCSNext 24/7/365 remote operations support through PlantFloor24 Sustaining Services Operational Consulting
Enterprise Integration
Industrial Automation
Improve quality, efficiency and safety of your plant Automation Solutions I&C Field Services Advanced Process Control
WEB RESOURCES
VIDEO
bit.ly/Maverick_5
WHITE PAPER
Maintenance Management ERP for Manufacturing Manufacturing Supply Chain Strategic Engagements
bit.ly/Maverick_4
WHITE PAPER
bit.ly/Maverick_3
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MAVERICK Technologies
About MAVERICK Technologies Founded in 1999, MAVERICK Technologies is the largest independent systems integrator in North America, and is a global leader in industrial automation, enterprise integration and strategic manufacturing solutions for clients across a wide range of manufacturing and process industries. Leveraging its unique enterprise-wide perspective, MAVERICK identifies suboptimal operations and improves performance for greater safety, efficiency and overall profitability. The companys people, processes and technical capabilities ensure delivery of the right solution for every project, using the most appropriate technology. Organizations around the world depend on MAVERICKs responsiveness, results-driven approach and dedication to their success. Over the years, MAVERICK has completed more than 10,000 successful projects in 45 countries across six continents.
LEARN MORE ON THE MAVERICK IDEAS BLOG Every day, MAVERICK employees connect with our customers on continuous process projects across a broad spectrum of industries. Now we're sharing our experiences with you through this blog. It's written by engineers, for engineers, and we hope it will help you take your operation to the next level. http://www.mavtechglobal.com/ideas/?s=continuous+process
COMPANY: MAVERICK Technologies
KeY coMPAnY contAct Jim Bouler phone: (850) 780-6477 EMAIL: james.bouler@mavtechglobal.com LIVE CHAT: Click here to live chat with Jim!
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Winsted
Winsted
Winsted is a worldwide leader in control room console solutions. We create attractive, ergonomic consoles that work with your operators to improve comfort and optimize efficiency. We offer stock, customized and custom consoles suitable for any control room application. Whether you are building a stateof-the-art control room from the ground up, or simply need to upgrade your operations, Winsted can provide the ideal solution. Our experts combine the disciplines of industrial design, ergonomics and interior design to create solutions that are both efficient and eye-catching. We give special consideration to the ergonomic requirements of your operators to build consoles that reduce fatigue, improve productivity and
COMPANY: Winsted
inspire. Our commitment to customer service is second-to-none and your satisfaction is guaranteed. Since its inception in 1963, Winsted has consistently been a pioneer in product design and development. Product concepts and designs are driven by industry needs and demands, with many product ideas WEB RESOURCES suggested by customers and developed with their input. Our modular system WhiTe PAper: approach, developed for the early Human Factors: Planning & Designing a Control Room broadcast industry, has become the http://winsted.com/img/ industry standard for all markets, and resources_literature/human_ factors.pdf our experience developing specialized custom products enables us to offer ONLiNe CATALog: console and furniture solutions for any http://catalog2012.winsted.com/ t1.asp application. A dominant factor in U.S. markets YouTube ChANNeL: for many years, Winsted expanded into http://www.youtube.com/user/ winstedcorp overseas markets in 1975, primarily
ProducTs:
http://winsted.com/products.htm
WEB: winsted.com
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Winsted
2010 and solidifies our mission of providing the highest quality console and furniture solutions to mission critical facilities around the world. In 2011, Winsted further expanded its custom capabilities with the launch of a new division. Winsted Custom Wood will focus on manufacturing custom cabinetry and millwork for control room installations. The Custom Wood Division enables Winsted to further expand our custom control room capabilities and fully realize our value proposition of offering stock, customized and custom console solutions to our customers. With the expansion, Winsted has added many skilled craftsmen who bring years of custom woodworking experience, as well as a state-ofthe-art production facility. Our family of companies, broad range of capabilities and an ongoing commitment to Customers, Products and Service is why Winsted is Preferred by Professionals Worldwide.
WEB: winsted.com
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