Plant Engineering 11-20117

41 Meet your 2017 Product of the Year finalists
PlantEngineering.com
New solutions
to old challenges
IIoT offers a fresh approach
to pipe fabrication 26
Affordable Process Control
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* See our Web site for details and restrictions. © Copyright 2017 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation
input #1 at www.plantengineering.com/information
COMPRESSORS
CSuccess
ustomerStory
Sweet Savings!
A compressed air audit opens a world of savings opportunities
PROBLEM: One of the world’s leading candy and gum manufacturers had no idea
how much their compressed air system was costing them. Four compressors (totaling
290 hp) supplied the air needed for pneumatic controls, packaging, and wax line extru-
sion applications. Excessive water in the compressed air lines, steep maintenance costs,
and high noise levels had them looking for a new solution.
SOLUTION: A comprehensive Air Demand Analysis (ADA) established a demand

profile for the plant and showed how they were using compressed air throughout the
week. It also identified areas of waste and inefficiency. By installing a 100 hp variable
frequency drive compressor and two 75 hp fixed speed compressors, they would have
all the air needed—with one of the fixed speeds acting as a back-up. This split sys-
tem solution would bring energy—and noise levels—well under control. A Sigma Air
Manager 4.0 master controller could provide on demand energy reports so they would
always know how their system was performing and what it was costing.
RESULT: In just over 9.5 months, the project has paid for itself. Annual energy costs
have been cut by more than 800,000 kWh. Part of these savings came from reducing
the plant pressure from 125 psi to 100 psi. Additionally, the new energy efficient dryers
installed have taken care of the moisture concerns. Needless to say, these savings
couldn’t get any sweeter.
Specific Power of Previous System: . . . . . . . . . . . . . . . . . . . . .47.16 kW/100 cfm
Specific Power of New System: . . . . . . . . . . . . . . . . . . . . . . . . .17.77 kW/100 cfm
Annual Energy Cost of Previous System: . . . . . . . . . . . . . . . . . . . . . . . . . $128,756
TOTAL ANNUAL ENERGY SAVINGS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,235
Utility Incentive:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,200
Let us help you measure and manage your compressed air costs!
Kaeser Compressors, Inc. • 866-516-6888 • us.kaeser.com/PE
Built for a lifetime is a trademark of Kaeser Compressors, Inc. ©2017 Kaeser Compressors, Inc. customer.us@kaeser.com
presence
The gift of global presents.
Thinking global, but

acting local.
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in 52 countries, SEW-EURODRIVE is truly a
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real local partner.
Whether you need inverter drives, motors, large

industrial gear units, or smaller gear units, you
can get the whole package from one source.
seweurodrive.com
NOVEMBER 2017
SOLUTIONS
Cover Story
26 | Capitalize on IIoT
to make better decisions
Improved data and analytics offer a greater
insight into efficiency
26 28 | Seven tips for proper bearing

maintenance
COVER: Smart technology also is being used to Load, use are keys to ensure longer opera-
improve operational uptime, by allowing for real- tional life.
time troubleshooting on the shop floor. Image
courtesy: Victaulic 31 | Industrial energy training and
certification
INSIGHTS Oak Ridge report details available how to
find, use industry resources.
7 | Saving time and money
with remote monitoring
10 | Lower the ‘normal’
cost of maintenance
12 | Six traits for great engineers
16 | Create a winning culture
on the plant floor
Research
18 | 2017 Safety Study
Five findings on plant safety
IIoT FOR ENGINEERS
Editor’s Insight 2 | Connect the physical with the digital
20 | Answering the big question: ‘What if?’
5 | Best practices for industrial cloud
computing delineated
INNOVATIONS
9 | Core technologies make edge
41 | 2017 Product of the Year Finalists intelligence possible
PLANT ENGINEERING (ISSN 0032-082X, Vol. 71, No. 9, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 3010 Highland Parkway, Suite #325, Downers Grove, IL
60515. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2017 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media,
LLC used under license. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515.
E-mail: customerservice@cfemedia.com. Postmaster: send address changes to PLANT ENGINEERING, 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515. Publications Mail Agreement No. 40685520.
Return undeliverable Canadian addresses to: 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA,
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foreign. Please address all subscription mail to PLANT ENGINEERING, 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims
any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
www.plantengineering.com PLANT ENGINEERING November 2017 • 3

WHY WE DO IT
CLEAN AIR
MATTERS
Farr Gold Series®

Dust Collector
camfilapc.com/videos/fgs
Handte EM Profi
Coolant Mist Collector
for machining
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Dust, Mist and Fume Collectors

AIR POLLUTION CONTROL
www.camfilapc.com • e-mail: filterman@camfil.com • 866-354-8794
INSIGHTS
Saving time and money
7 As a viable and cost-effective solution,
many facilities have implemented remote
monitoring to help anticipate machine
maintenance, improve operating efficiencies,
and save money.
“ As the Internet of Things (IoT)

technology spreads through the modern
Lower the ‘normal’
cost of maintenance
production environment, the need for a New integrated enterprise
strategic approach to asset management is

asset management systems pay
companies back by optimizing
10
soaring, and the benefits of adopting EAM the efficiency and reliability of the
”
core equipment and processes
are going into overdrive. that managers depend on daily.
RESEARCH Six traits for great

engineers
2017 Safety Study
Five findings of plant safety
Anyone can be an engineer, but
great engineers are a rare breed. 12
These six traits are the ones that
18 56% make some engineers rise above

the rest.
of engineers have observed a direct

and positive impact on productivity Create a winning culture
as a result of implemented safety on the plant floor
procedures at their facilities.
In the future, maintenance
will focus on improving and
maintaining and being a critical 16
EDITOR’S INSIGHT part of the team along with
production. Each has a clear role
20 Answering the big
to play. Production needs to be
a strong offense; maintenance a
question: ‘What if?’ strong defense.

Reduce the Risk of
Arc Flash with the
Right Expertise
With the right NFPA expertise, you can help reduce the risk of arc
flash incidents at your facility. Brady Safety can help you build a
sustainable safety system with our:
• Arc flash audits
• Arc flash assessments
• Arc flash onsite training
Learn more and download the Arc Flash

Regulatory Summary at BradySafety.com
INSIGHTS
By Brian Blum, Atlas Copco Compressors
Saving time and money

Three ways to improve operations with better data access
P
lants and manufacturing facilities often know exactly what’s going on with your machines
encounter machine breakdowns due without having to be physically present on the
to missed maintenance. The cost of a plant floor.
breakdown extends far beyond the cost
of repair – it also impacts production, product How does it work?
quality, shipping schedules and the bottom line. Remote monitoring collects and sends information
As a viable and cost-effective solution, many facili- straight from the controller, using sensors that are
ties have implemented remote monitoring to help placed on each machine you wish to monitor. With
anticipate machine maintenance, improve operat- this technology, plant managers get complete insight
ing efficiencies and save money. into their machines’ production when viewing the
Remote monitoring is just what the name online system dashboard or when they receive noti-
implies – having the ability to monitor machines fications and updates via email and text messaging.
from afar with automated data collection that you
can access anytime, anywhere. That means you What types of information does
it provide?
Remote monitoring provides machine data on com-
Remote monitoring of compressed air systems helps anticipate ponents such as temperature, pressure, volume,
machine maintenance, improve operating efficiencies and saves energy consumption, loaded hours, and unloaded
money. Image courtesy: Atlas Copco hours. These data points can be exported as graphs
so users can see trends and use
them to predict potential problems
and set a maintenance schedule to
avoid expensive machine failures.
Who manages the

remote monitoring
system?
• Internally: Within the plant
and manufacturing facility,
alerts and notifications can be
sent to select employees. These
employees also can access the
dashboard for detailed infor-
mation, data, trends and more.
• Externally: Typically, the

remote monitoring provider
also can oversee machine
operations and processes in
case there is a need for imme-
diate service. This helps to
significantly reduce response

More Choices
Representing North America’s leading industrial brands

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located throughout North America for your convenience
Scan to watch
Expect More With Motion.

http://esp.to/wyBAdg
Call. 800-526-9328
Click. MotionIndustries.com
Visit. Over 530 Locations
©2017 Motion Industries, Inc.
Advertorial
INSIGHTS
time when it comes to repairing the equipment, which also minimizes machine
downtime.
Hey Buddy…Fix Me!!
Benefits of remote monitoring Did you ever imagine that the day would come
when machines would actually tell you when
1. Saves time and increases efficiency they need to be maintained or repaired? Just
Remote monitoring can reduce the plant’s labor costs. Employees no longer think about it, how many products in your home
have to continuously check on each machine on the plant floor and record tell you they need attention. Your air conditioner
production times and data points. Employees can focus on analyzing the data tells you to replace the air filter. Your alarm
as opposed to collecting it. system tells you to replace the backup battery.
Remote monitoring sensors can be placed on machines located in remote, Your car will let you know when it is time for an
hazardous and hard-to-access places. This allows plant managers and employ- oil change…and remind you again it you forget
ees to monitor all machines regardless of location and receive automated data to do it. So it only makes sense that these
throughout the day to save time and increase efficiency. technologies make their way onto the industrial
Staying connected throughout the day keeps plant managers on top of manufacturing floor as technologies continue to
machine performance and energy consumption. When malfunctions arise, advance.
they are immediately recognized by the system and can be addressed to avoid
downtime. Its analysis reporting function also allows users to identify if the Today, almost every-top shelf manufacturer of
correct machine is running based on application demand so no energy is products used to make other equipment run are
wasted. Data parameters, temperature, pressure, loaded hours and unloaded developing a roadmap based around intelligent
hours can all help to make informed decisions about increasing operating monitoring and maintenance. With Industry
efficiency. 4.0 and IIoT all the rage, don’t be surprised to
see more and more of the sensor technologies
2. Provides proactive maintenance currently used in residential and commercial
It’s always better to be proactive rather than reactive. With remote machine applications make their way to the industrial
monitoring, plant managers and employees receive alerts when the system plant floor…in fact, it is already happening!
senses machine irregularities and errors. Warnings are sent before a complete
To remain globally competitive, many manu-
machine shutdown occurs so plants can fix the problem immediately to avoid
facturers are finding the right applications to
unnecessary downtime. Some remote monitoring systems can even request
employ plant floor automation and robotics. In
service quotes for any maintenance that’s needed.
many cases, this
Remote machine monitoring can also send notifications when scheduled
new automation
maintenance is due or when it has been missed. These service checks help
equipment will
ensure that machines are performing at their optimal level and not wasting
diagnose itself on
energy. This is also a time when audits can be done to see if machines are
a scheduled basis
sized correctly to support plant applications.
and provide a ma-
3. Receive valuable insight chine health report
to the operator. So
Remote monitoring data is useful when it comes to finding trends based
maybe the equip-
on energy use and maintenance. The software can produce graphs so it’s
ment won’t actually
easy for plant managers to compare data points week over week, month over
say “Fix Me” but
month, and year over year. These trends provide insight into whether or not
sends a signal that
some machines are working harder than others, when maintenance normally
lights up an alert on a control panel or possibly
occurs and what fixes can be made to optimize operations.
even shuts the equipment down before cata-
Save time and money when you can have access to the machine data you
strophic failure speaks loud enough.
need throughout the day from wherever you are. Remote monitoring helps
you make intelligent decisions with important data insight that allows you to: At Motion, we are seeing more and more plants
• Cut labor costs with less physical monitoring of your machines. move to smart products on applications such as
material handling conveyors, pumps, large elec-
• Receive notifications and alerts to schedule service intervals for your tric motors and more. So watch out, pretty soon
machines that help avoid costly downtime and equipment failure. the equipment in your plant may be smarter
than a 5th grader!
• Evaluate data trends over select periods of time to determine if machines
are operating efficiently. PE Randy Breaux
Senior VP Marketing, Distribution,
Brian Blum is a product marketing manager for connectivity and optimiza- and Purchasing
tion at Atlas Copco Compressors LLC in Rock Hill, S.C. Motion Industries
INSIGHTS
By Kevin Price, Infor
Lower the ‘normal’ cost of maintenance

Better parts visibility keeps the machinery of manufacturing running.
L
ooking at the way maintenance and parts optimizing the efficiency and reliability of the core
inventories have evolved a more strategic equipment and processes that managers depend
approach to enterprise asset management on daily.
(EAM) in recent years, it is apparent that
visibility is one of the most important drivers at Visibility at every stage
every step in the process. The shift to EAM emphasizes visibility through-
There was a time when the process for maintain- out the asset management universe.
ing mission-critical equipment and replacing com- Sensors monitor every step in a business process,
ponents when they failed was deceptively simple. every device or component it depends on, and
The unit failed, or it began to perform so far outside issue real-time warnings when a piece of equip-
expected parameters that it clearly needed attention. ment falls outside its normal operating parameters.
A maintenance team checked it and got it back in The monitoring system quickly accumulates a
working order. mass of historical data that is more reliable and
If they needed a part, they took it out of inven- easily accessible than paper records, and much
tory. If there was no inventory in stock, they ordered more effective at pinpointing the early signs of
it, and the repair was eventually done, whenever equipment stress and predicting failures before
the part arrived. they occur.
For some companies, that is still the way things The user dashboards at the front end of the
are done. (After all, they might say, it’s the way we’ve system deliver proactive alerts and key metrics
always done them.) But chances are, these compa- and performance reports, providing the right level
nies do not enjoy the fact that their maintenance of tactical detail or aggregate analysis at different
systems cost them more than they should—in more levels within an organization.
than one way. At its most basic, an EAM system does a better
It is more expensive to rush in a part on an urgent job of tracking what’s going on with the critical
basis than to post a routine order. If an essential equipment and infrastructure a business depends
piece of equipment has failed, it can bring a whole on every day. However, its real power is demon-
line to a sudden, screeching halt until it is back up strated in the deployment of data to set targets,
and running. boosted efficiency, optimized distribution of
If your first inkling of a failing part is that a equipment and maintenance personnel, and sav-
machine has stopped working, it probably means ings that go straight to the company’s bottom line.
the unit has been sub-optimal for some time, slow-
ing down or complicating the Soaring to greater heights
M More
INSIGHTS
business process that depends
on it. The final failure might
even damage the equipment
As the Internet of Things (IoT) technology
spreads through the modern production envi-
ronment, the need for a strategic approach to
Looking for more information on much more than if the ini- asset management is soaring, and the benefits of
enterprise asset management? Go tial problem had been caught adopting EAM are going into overdrive.
to www.plantengineering.com and sooner. An integrated EAM system spots the problem,
type EAM into our search engine to There was a time when a supports a timely response, triggers the purchas-
find these and other articles: purely reactive approach to ing system to replace spare parts before they’re
maintenance management was needed again—then applies the decision to future
Lines blurring between CMMS the only choice companies had. challenges, becoming smarter all the time.
and EAM Those days are gone—great It’s a far cry from the paper-based systems that
news for anyone who wants generations of plant engineers have had to settle
The first three steps are always
to run an efficient business or for. PE
the hardest
public sector organization.
Finding the right tools to delve New integrated EAM sys- Kevin Price is the technical product evangelist
into process data. tems pay companies back by and strategist for Infor.
10 • November 2017 PLANT ENGINEERING www.plantengineering.com

The Truth About Compressed Air!
If you think compressed air is too expensive and noisy - read this. The facts will surprise you!
Compare these Blowoffs Facts about Blowers

There are a variety of ways to blow the water from the bottles shown in the photo below, Energy conscious plants might think a
but which method is best? To decide, we ran a comparison test on the same application blower to be a better choice due to its
using four different blowoff methods: drilled pipe, flat air nozzles, Super Air Knife (each slightly lower electrical consumption
using compressed air as a power source), and a blower supplied air knife (using an electric compared to a compressor. In reality, a
motor as a power source). Each system consisted of two twelve inch long air knives. The blower is an expensive capital expenditure
following comparison proves that the EXAIR Super Air Knife is the best choice for that requires frequent downtime and
your blowoff, cooling or drying application. costly maintenance of filters, belts and
bearings. Here are some important facts:
The goal for each of the blowoff choices was to use the least amount of air possible to
get the job done (lowest energy and noise level). The compressed air pressure required Filters must be replaced every
was 60 PSIG which provided adequate velocity to blow the water off. The blower one to three months.
used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. Belts must be replaced every
The table at the bottom of the page summarizes the overall performance. Since your three to six months.
actual part may have an odd configuration, holes or sharp edges, we took sound level Typical bearing replacement is at least once
measurements in free air (no impinging surface). a year at a cost near $1000.
• Blower bearings wear out quickly due
Drilled Pipe Blower Air Knife to the high speeds (17-20,000 RPM)
This common blowoff is very The blower proved to be an expensive, noisy required to generate effective airflows.
inexpensive and easy to make. For this option. As noted below, the purchase price
test, we used (2) drilled pipes, each is high. Operating cost was considerably • Poorly designed seals that allow dirt and
with (25) 1/16" diameter holes on 1/2" lower than the drilled pipe and fl at air moisture infiltration and environments
centers. As shown in the test results nozzle, but was comparable to EXAIR’s above 125°F decrease the one year
below, the drilled pipe performed Super Air Knife. The large blower with bearing life.
poorly. The initial cost of the drilled its two 3" (8cm) diameter hoses requires
pipe is overshadowed by its high energy significant mounting space compared to • Many bearings can not be replaced in
use. The holes are easily blocked and the others. Noise level was high at 90 dBA. the field, resulting in downtime to send
the noise level is excessive - both of There was no option for cycling it on and off the assembly back to the manufacturer.
which violate OSHA requirements. to conserve energy like the other blowoffs.
Velocity across the entire length Costly bearing and filter maintenance along Blowers take up a lot of space and often
was very inconsistent with spikes with downtime were also negative factors.
of air and numerous dead spots.
produce sound levels that exceed OSHA
noise level exposure requirements. Air
Flat Air Nozzles EXAIR Super Air Knife volume and velocity are often difficult to
As shown below, this inexpensive The Super Air Knife did an exceptional control since mechanical adjustments are
air nozzle was the worst performer. job of removing the moisture on one pass required.
It is available in plastic, aluminum due to the uniformity of the laminar
and stainless steel from several airflow. The sound level was extremely To discuss an application, contact:
manufacturers. The flat air nozzle low. For this application, energy use was
EX AIR Corporation
provides some entrainment, but suffers slightly higher than the blower but can be
from many of the same problems less than the blower if cycling on and off 11510 Goldcoast Drive
as the drilled pipe. Operating cost is possible. Safe operation is not an issue Cincinnati, Ohio 45249-1621
and noise level are both high. Some since the Super Air Knife can not be dead- (800) 903-9247
manufacturers offer flat air nozzles ended. Maintenance costs are low since Fax: (513) 671-3363
where the holes can be blocked - there are no moving parts to wear out. email: techelp@exair.com
an OSHA violation. Velocity was www.exair.com/79/423.htm
inconsistent with spikes of air.
See the Super Air Knife in action.
The Super Air Knife is the low cost way www.exair.com/79/akvideo.htm
to blowoff, dry, clean and cool.
Blowoff Comparison
Comp. Air Sound Annual Approx. Annual First
Horsepower Purchase
Level Electrical Maintenance Year
Required Price
Type of blowoff PSIG BAR SCFM SLPM dBA Cost* Cost Cost
Drilled Pipes 60 4.1 174 4,924 35 91 $50 $4,508 $920 $5,478
Flat Air Nozzles 60 4.1 257 7,273 51 102 $208 $6,569 $1,450 $8,227
Blower Air Knife 3 0.2 N/A N/A 10 90 $5,500 $1,288 $1,500 $8,288
Super Air Knife 60 4.1 55 1,557 11 69 $594 $1,417 $300 $2,311
*Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.
INSIGHTS
By Jessica Potts, TopEngineer
Six traits for great engineers

Curiosity, organizational skills—and great communicators are needed.
G
reat engineers are competent, creative, 4. Good analytical skills
yet logically practical, and incredibly There is a world of difference between something
influential on everyone’s daily lives. And working and something working well. Engineers
yet, for some, the thought of being an are typically tasked with finding the most efficient
engineer seems like an unattainable and distant solution to a problem, which requires being able to
goal that can never be achieved. The truth is that analyze the issue as well as all possible answers to
anyone can be an engineer, but great engineers are identify the best course of action. Analytical abil-
a rare breed. These six inherent traits are the ones ity comes in many shapes and forms; even English
that make some engineers rise above the rest. majors must be analytical in some sense. However,
engineers’ analytical minds are constantly run-
1. They’re naturally curious ning, revising plans to ensure the best possible
Engineers must be able to observe a process, struc- outcomes. People who are able to logically pick
ture, machine, or system and determine how it problems apart and discover optimal solutions on
works and how they can improve upon it. Curios- the fly have the right stuff as a potential engineer.
ity is a beneficial quality in nearly every industry
because it indicates interest and drives creativity. 5. Strong mathematical skills
Engineers must have the energy and determination In every engineering discipline, from computer
to research and understand problems and their engineering to petroleum engineering, you will
solutions and it starts with that natural curiosity. work with numbers and equations. At its very
Kids who grew up asking, “Why?” are good can- core, engineering is the application of theoretical
didates for engineering programs - but those who mathematics to the physical world to solve every-
excel at engineering are more often those who pur- day problems. Engineering programs are often
sue “Why?” to “Oh, that’s why.” Asking questions rigorous in mathematical studies, putting students
isn’t enough for an engineer; they want to find out through advanced calculus, statistics, trigonom-
the answer and are willing to spend as much as time etry, and geometry. Students curious about engi-
it takes until they reach a satisfying conclusion. neering should be confident and comfortable in
writing and using formulas to solve problems
2. They are self-organized because it will be required after graduation.
Engineering teams usually have managers tasked
with keeping workers on course, but most engi- 6. Good communication skills
neers still must be able to manage their own proj- While engineers may seem to be asocial, numbers-
ects to some degree. Often, engineering projects focused professionals, they are far from hermits.
last months or years, and ideas or discoveries made Engineers almost always work in teams, which
long ago must be readily available for application. means communication between team members
Even better, by displaying project management occurs on a regular basis. Communication failures
skills, you are more likely to obtain raises and within engineering result in low-quality machines,
promotions. Fortunately, self-organization is one inefficient systems, and worse. So the ability to
of the few top engineering qualities that can be express thoughts and opinions must be finely
improved upon with concerted effort. honed.
As with project management skills, engineers
3. They are detail-oriented who prove themselves adept at communication
To succeed in engineering, the person needs to be often excel in management positions. Thus, if you
able to parse details and organize them to create believe your ability to communicate is above and
an effective machine—process, system, structure. beyond the average engineer’s, you should consider
This is part of an engineer’s daily responsibili- advanced education to prepare you for your accel-
ties and such attention to detail allows engineers erated career in engineering. PE
to analyze intricate problems and produce high-
quality work. Jessica Potts is head of marketing at TopEngineer,
a CFE Media content partner.

FUTUREPROOF
YOUR SUPPLY CHAIN AT MODEX 2018
Industry 4.0 and the Industrial Internet

of Things are here, and they’re impacting
manufacturing and supply chain
operations every day.
Georgia World Congress Center
At MODEX, you’ll find the insight, perspective Atlanta, Georgia
and solutions necessary to face today’s toughest April 9-12, 2018
challenges head on.
With over 850 of the industry’s leading manufacturing THE GREATEST SUPPLY CHAIN
and supply chain solution providers on hand, you’ll SHOW ON EARTH.®
have access to efficiency-enhancing and cost-cutting
innovations that will help you exceed customers’
demands. The industry’s greatest minds will also
be there, sharing their expertise on the show floor,
during powerful keynotes and through 100+ hands-on
education sessions.
By attending MODEX, you’ll not only find your edge —

you’ll futureproof your supply chain for years to come.
MODEX is FREE to attend.
LEARN MORE AND REGISTER AT MODEXSHOW.COM.

NOTABLE
Dick Morley, ‘father
of PLC’ dies at 84
Richard “Dick” Morley, an electrical engineer named the “father” of the
Reliability
programmable logic controller (PLC) passed away on Oct. 17 in New Hamp-
shire at the age of 84. Morley was the founder and president of Bedford
Associates, where he created Modicon, the first PLC, in 1968.
In 2008, Control Engineering covered Morley’s contributions to the PLC
is everything and to automation as a whole in an article designed to honor the 40th
Gerald “Gerry” Bauer anniversary of the technology.
President, EccoFab - Rockford, IL The project came about because they were frustrated at spending several
 Sullair.com/GerrysStory months getting a minicomputer installation running properly at a client
site. It was especially frustrating because the projects Bedford did were
similar. Morley considered the idea of building a computer-like control
unit that could replace minicomputers for machine tool control and parts
handling. On January 1, 1968, Morley composed a 12-page document that
would become the earliest documentation for PLC development.
Morley, who was also a contributor to Control Engineering and Plant
Engineering, wrote about that process in a 2008 article:
“The hardware had to look good to manufacturing, be power- and voltage-
insensitive, rugged and high priced,” Morley wrote. “I knew then cost was
a bad word. We believed our user would want total value, not entry costs.
If the programmable controller saved one month of factory up-time, it was
worth a million dollars.
It doesn’t quit.
It doesn’t even think about quitting.
In fact, it doesn’t think of anything
but the job at hand.
Sound familiar?
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“At that time, we did not know what we had built. We just wanted to get
treatment products, contact your local distributor or
rid of a problem that had plagued me for four years in specialized systems.
visit our website. What it did for the customer was reduce the time to market from months
to weeks on a greenfield project, and maintenance was really low—it runs
forever.”
Condolences for Morley came from many in the manufacturing and auto-
input #10 at www.plantengineering.com/information mation industry for his contributions to the industry. “In ushering in the
era of modern automation, he served as a longtime mentor and friend to
many of our leaders and to countless other professionals within the pro-
cess automation and manufacturing industry, unfailingly offering thought-
provoking and challenging advice to those who needed it,” Schneider Elec-
tric said in a statement. PE
© 2017 Sullair, LLC. All rights reserved.

A collection of news
and other items
Sharp decrease
in 2016 OSHA
workplace
violations
The annual OSHA Top 10 work-
place safety violations list is notable
in 2017 not for the order of violations,
but for the sharp decrease in the num-
ber of reported safety violations.
Announced Sept. 26 at the National
Safety Council’s Congress and Expo
in Indianapolis, the OSHA Top 10 list
saw no change among the top five vio-
lations. Fall protection remains the
most often cited safety violation, but FOR THE CONSTRUCTION
AND EQUIPMENT INDUSTRY,
there was a 14% decrease in violations
from 2016 (6,929) to 2017 (6,072). The
announcements were made by Patrick
Kapust, deputy director of OSHA’s
Directorate of Enforcement Programs.
IN AMERICA’S MANUFACTURING
There were similar drops for the
other Top 4 violations: HEARTLAND
tHazard Communication: down
35.9% from 5,677 in 2016 to 4,176
in 2017
Connect with the entire supply chain – designers &
manufacturers, engineers & suppliers, distributors &
tS caffolding: down 18.8% from end users at the world premier fastener exhibition in
3,906 in 2016 to 3,288 in 2017
the Center of America’s manufacturing base.
tR espiratory Protection: down
15.7% from 3,585 in 2016 to 3,097 Learn about the latest technologies
in 2017
and meet with experts at the first DON'
tL ockout/Tagout: down 18.7% Fastener Fair in the USA. MISS T
OUT..
from 3,414 in 2016 to 2,877 in
REGIS .
TE
2017.
The next five violations were lad- TODA R

ders, powered industrial trucks,
machine guarding, fall protection—
Y!
training methods, and electrical—wir-
ing methods. All categories showed
APRIL 11-12, 2018
similar drops from 2016, and all cat- HUNTINGTON CONVENTION CENTER,
egories were also down significantly CLEVELAND, OHIO USA
from 2015. The only exception was fall
protection—training methods, which For more Information, please contact us at:
did not make the top 10 list in either Email: fastenerfairusa@mackbrooks.com
2015 or 2016. PE Telephone: 312.809.9260
November 2017 t 15 www.fastenerfair.com/usa

INSIGHTS
By Chris Vavra, CFE Media
Create a winning culture on the plant floor

Focus on operational improvement rather than maintaining what you have.
C
an you imagine a football game where Four rules for winning the game
you don’t keep score? What if the coach Companies that want to improve their efficiency
doesn’t even go to the games? What if the can go from maintaining to improving by follow-
players don’t know what position they’re ing these four rules:
in? We know that’s not the reality.
But a similar situation happens all the time in 1. Visibility and transparency.
manufacturing, said Mark Hungerford, director of Have some way everyone can score. Are we slid-
customer services at Leading2Lean, during his pre- ing back, or are we just simply maintaining? The
sentation, “Using Cloud Technology for Plant Floor collected maintenance data is used by all and
Efficiency at West Liberty Foods,” at the Process decision are made based on data rather than emo-
Expo in September in Chicago. “People who need tions. Transparency allows workers to see what
to know aren’t in the game,” Hungerford told the works and what doesn’t, as well as which depart-
audience. “They don’t have the information they ments or people are not carrying their weight.
need. They don’t know if they’re winning or losing.”
Hungerford noted that, “Ninety-nine percent of 2. Real-time visibility.
the plants I go into are operating this way. Managers “You need to be able to adjust in real-time dur-
aren’t there or they receive the information late. We ing the game,” Hungerford said. “If the offense
can’t imagine that in a professional football environ- isn’t working, they need to know now so they
ment, so how do we avoid that on the plant floor?” can make adjustments.” This means there needs
Maintenance hasn’t changed much, according to be instant access to data and instructions and
to Hungerford. Many don’t see it as a value-added real-time communication through the appropri-
process. They’re out of sight, and they don’t know ate departments.
if they’re winning or losing. Technicians experi-
ence déjà vu as they fix the same problems, and 3. Make sure people have the right tools.
they don’t know if they’re contributing to the The tools should compliment the process rather
problem. than burden it, Hungerford said. Real-time tools
encourage real-time decision-making, and they
Strength on both sides provide personal value to the user and to the
The maintenance of the future, Hungerford said, company as a whole. Those tools, Hungerford
will focus on improving and maintaining and said, have changed, and mobile has become the
being a critical part of the team along with pro- new standard on the plant floor.
duction. Each has a clear role to play. Production
needs to be a strong offense; maintenance a strong 4. Focus on continuous improvement.
defense. And both sides, Hungerford said, need Companies that know they are good shouldn’t
to learn from one another so they can help each rest on their laurels. Hungerford used an example
other understand how each department’s actions related to Formula One pit stops. In the 1950’s, a
improve the bottom line. pit stop took 67 seconds. In 2017, it takes less than
Maintenance of the future requires a different two seconds. That’s continuous improvement.
mindset to be successful. Technicians need to be Doing the small things right and learning from
engaged and contribute their creativity to improve your mistakes, Hungerford said, are part of con-
the design of product equipment, processes, and tinuous improvement. And when a problem con-
overall efficiency. Instead of maintaining, workers tinues to come up, workers need to know how to
should be giving them the tools and the expecta- problem-solve. That’s not always easy, he said,
tion to improve. and it takes practices, but keeping at it will be
“It’s time to eliminate the maintenance depart- beneficial in the long run. PE
ment and replace it with the improvement depart-
ment,” Hungerford said. “Do we really want to Chris Vavra is production editor for CFE Media.
just maintain?” Leading2Lean is a CFE Media content partner.

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M More
RESEARCH
Plant Engineering covers several
research research topics each year.
All reports are available at

www.plantengineering.com/research
2017 SAFETY STUDY:
Five findings on plant safety
R
espondents to the Plant Engineering 2017 Safe- of industries and insurance claims have also decreased
ty Study indentified five high-level findings since following a safety program.
impacting the manufacturing industries today:
4. Enforcing safety: More than 78% of facilities hold
1. Commitment to safety: Seventy-one percent of regular safety meetings, perform safety audits, and have
operations personnel and 69% of senior management established a safety committee to enforce safety meth-
are very committed to safety in their facilities, followed ods. Another 74% have implemented job safety analysis
by line supervisors (68%) and line workers (53%). procedures and 68% discipline, suspend, and/or termi-
nate staff for irresponsible actions.
2. Work group safety: The work groups that feel the
safest in their daily tasks are plant management/cor- 5. Safety strategies, technologies: The top strategies
porate executives (73%), safety executives/managers or technologies that facilities use to support safety pro-
(65%), and engineering (64%). cedures include personal protective equipment (90%),
lockout/tagout procedures (84%), job safety analysis
3. Safety programs: Ninety-four percent of respondents (76%), and internal safety audits (66%).
believe their employees feel safe on the job, and 83%
have observed an increase in productivity over time due View more information at
to the implementation of a safety program. The costs www.plantengineering.com/2017Safety.
Amanda Pelliccione is research director

at CFE Media.
Safety meetings are generally held

on a monthly or weekly basis, and the
most active contributors are mainte-
nance personnel (66%), safety execu-
tives/managers (61%), operations
(60%), and plant management/corpo-
rate executives (60%). Source: Plant
Engineering
42% ofeither
facilities monitor their natural gas usage
twice a year or on a continual basis.
Source: Plant Engineering 2016 Energy Management Study
50% ofspreadsheets/schedules
facilities use a CMMS or in-house created
maintenance.
to monitor or manage
Source: Plant Engineering 2017 Maintenance Study
56% ofpositive
engineers have observed a direct and
impact on productivity as a result of The average plant engineering professional
implemented safety procedures at their facilities. earned a bonus of $9,100 in 2016. Source:
Source: Plant Engineering 2017 Safety Study Plant Engineering 2016 Salary Survey

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quickly. Starline Track Busway can be tapped instantly at any location, without
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GLVWULEXWLRQDQGPRQLWRULQJV\VWHPRIFKRLFHYLVLWVWDUOLQHSRZHUFRP

INSIGHTS
By Bob Vavra, Content Manager
PlantEngineering.com
Answering the big question: ‘What if?’ 3010 Highland Parkway Suite 325
Downers Grove, IL 60515
Ph. 630-571-4070, Fax 630-214-4504
If you analyzed 70 years the biggest question every

of articles in Plant Engi- plant manager must face:
CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager
neering, you’d find we “What if?” BVavra@CFEMedia.com
essentially write about • What if I could shave EMILY GUENTHER, Associate Content Manager
three things: people, pro- time off my production EGuenther@CFEMedia.com
cesses, and products. On process? AMANDA PELLICCIONE, Director of Research
APelliccione@CFEMedia.com
the people side, we discuss • What if I could reduce
CHRIS VAVRA, Production Editor
training, safety, and worker downtime? CVavra@CFEMedia.com
development. On the pro- • What if my automa- SIERRA GRAYSON, Marketing & Production Coordinator
cess side, we look at operation system showed me SGrayson@CFEMedia.com
tional strategy and how to where there were weak-
use technology effectively. nesses in my process? EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow
When it comes to prod- • What if I had better H.Landis.Floyd@gmail.com
ucts, we offer our readers insight into my plant
SHON ISENHOUR, Partner, Eruditio LLC
the latest product develop- assets? sisenhour@EruditioLLC.com
ments, from the smallest sensor to the larg- • What if I knew where the leaks were in DR. SHI-WAN LIN, CEO and co-founder, Thingswise, LLC
est compressor or motor. We also offer some my compressed air system? Industrial Internet Consortium (IIC) board member
shiwanlin@thingswise.com
insight on how to more effectively use those Product of the Year’s goal is to high-
DAVE REIBER, Senior Reliability Leader, Reliabilityweb.com
products to achieve process goals. light this innovation, hand out some really dave.reiber@reliabilityweb.com
Plant Engineering’s New Products impressive trophies, but most of all, to
DAVID SKELTON, Vice president and general manager
For Engineers database now available at answer that ‘What if?’ question. Regardless Phoenix Contact Development and Manufacturing
www.plantengineering.com, offers a one- of which products our readers ultimately dskelton@phoenixcontact.com
stop shop for all the latest products, sortable choose to receive the Gold, Silver, and BILLY RAY TAYLOR,
Director of commercial and off-highway manufacturing
by product category. And every year at this Bronze awards in each category, a review The Goodyear Tire & Rubber
time, we offer the analog version of that of all of these products gives plant managers Billytaylor@goodyear.com
digital list: the annual Product of the Year a way to find the answers. LARRY TURNER, President and CEO, Hannover Fairs USA
competition. In the day-to-day operational mode most lturner@hfusa.com
Now in its 30th year, Product of the Year plants are in, it’s hard to find the time to take MARK WATSON, Senior director, manufacturing technology,
IHS Markit
remains the most coveted new product a breather, step back and see how things Mark.watson@ihsmarkit.com
award in the industry because the win- could be better. Yet that kind of evaluation
ners are selected by our qualified readers. is essential to improve, and continuous CFE MEDIA CONTRIBUTOR
We only allow people who buy or specify improvement has been at the forefront of GUIDELINES OVERVIEW
Content For Engineers. That’s what CFE Media stands for,
products in their manufacturing plant to Plant Engineering’s message to our audience and what CFE Media is all about—engineers sharing with their
cast votes, and we disqualify a fair number for the last 70 years. peers. We welcome content submissions for all interested
parties in engineering. We will use those materials online, on
of votes each year from people who don’t This particular issue of Plant Engineering our Website, in print and in newsletters to keep engineers
meet that voting qualification. (I mention is a great time to stop, take a few minutes, informed about the products, solutions and industry trends.
and leaf through this issue to take a look * www.plantengineering.com/contribute explains how to
this both as encouragement to all of you who submit press releases, products, images and graphics, bylined
do vote and as a reminder to those folks who at what manufacturing innovations await feature articles, case studies, white papers, and other media.
try to slip a few votes past us. We’ve been at you in the coming year. These are the best * Content should focus on helping engineers solve prob-
lems. Articles that are commercial in nature or that are critical
this 30 years. Trust me—we check.) new ideas in the market, from fundamental of other products or organizations will be rejected. (Technol-
Product of the Year is one of my favor- maintenance products to the latest automa- ogy discussions and comparative tables may be accepted if
non-promotional and if contributor corroborates information
ite issues because it’s all about continuous tion innovations. Any of them can help your with sources cited.)
innovation, and that should be exciting to plant improve. All of them show the supplier * If the content meets criteria noted in guidelines, expect
to see it first on our Websites. Content for our e-newsletters
everyone in manufacturing. To the many community’s commitment to look for new comes from content already available on our Websites. All
companies who entered Product of the Year ways to help plant operations move forward. content for print also will be online. All content that appears
in our print magazines will appear as space permits, and we
in 2017—we have more than 100 qualified Please review this year’s Product of the will indicate in print if more content from that article is avail-
entries—it’s an affirmation that they are Year Finalists. Please evaluate these great able online.
always looking for new ways to improve their new ideas against your own needs. And * Deadlines for feature articles intended for the print maga-
zines are at least two months in advance of the publication
contribution to the manufacturing plant. please vote. All of this helps you get better date. Again, it is best to discuss all feature articles with the
These product innovations emerge each as a manufacturing operation. content manager prior to submission.
year from continuing conversations between And it keeps you from having to answer Learn more at:
product managers and plant personnel. It’s the bigger question: “What if we DON’T www.plantengineering.com/contribute
that conversation that leads to the answer to improve?” PE

Farr Gold Series® Breaks the Mold on
Dust and Fume Collection
Summary:
Watts Water Technologies, Inc. is a leading manufacturer
of valves and other products for water heaters and boilers.
When Watts built a 42-acre addition at their Franklin, New
Hampshire location, the company decided to integrate
high-efficiency dust collection equipment. This equipment
would help them meet tightening industry standards while
handling their production facility’s rigorous demands.
Watts selected Farr Gold Series® (FGS) dust collectors to

handle its various manufacturing processes including sand
removal, pouring, and finishing. Because FGS collectors
are built modularly, the best size, configuration and CFM
could be installed for each area and application.
Challenge:
After expanding their operation, Three Farr Gold Series dust collection systems were installed that utilize a
valve manufacturer Watts Water variable-frequency drive system with a 200-horsepower fan to modulate
Technologies, Inc. was looking the fan speed and maintain a constant static pressure.
for a high-efficiency dust
collection system to maintain a • GS108 - includes a mining inlet to
handle large volume of green sand with
clean working environment and
high clay and moisture content.
ensure employee safety.
• GS96 - collects metal fumes from
the melting system. Two inlets serve
Solution: different mill areas and a spark trap inlet
Three Farr Gold Series® dust combats potential fire hazards.
collection systems were installed • GS72 - handles finishing processes
to capture the dust, sand and that create very heavy dust, including
liquid metal fumes produced by metal grinding and shot blasting. It has
the foundry’s manufacturing abrasion resistant inlets, channel baffles
processes. and HEPA filtration.
The HEPA filters bring air into the

Result: foundry to save on heating costs
The Farr Gold Series collectors are during cold New Hampshire winters.
now essential to the company’s Each unit moves 50 to 60,000 cubic
operations, providing improved feet per minute of air, which can be directed back into the building as
air quality and energy savings. heat. Watts has witnessed tangible benefits from the units, including
Watts continues to appreciate lower energy costs and enhanced air quality.
the equipment performance and
durability as well as Camfil APC’s
technical support. 870-933-8048
filterman@camfil.com
www.camfilapc.com

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NEW VeriSafe™ Absence Of Voltage Tester–

Improving Efficiency and Reducing Cost
When servicing electrical equipment, workers must maintenance, and

comply with safety regulations that require a voltage repair workers.
verification test to validate the absence of voltage. This These injuries are
process requires strict adherence to prevent accidents often costly and
and bodily injury, but includes many stages that can be serious, so any
complex and time-consuming when using hand-held opportunity to
portable test instruments. This paper examines the costs decrease the risk of
and limitations involved with using a manual absence of these dangerous
voltage tester. It also describes a new technology for the electrical hazards is examined by safety product
factory floor that automates the process, reducing time, engineers and manufacturers with an attention to detail.
complexity, and costs.
The newest revision of NFPA 70E-2018 will include
revised language around absence of voltage verification,
specifically in Article 120.5 (7). This revision will include
an exception, also known as an approved alternative,
to using a handheld test instrument to determine the
absence of voltage. The new exception describes an
absence of voltage tester. Part of the motivation for
including this exception in the revised standard was to
make testing for an absence of voltage safer and
more efficient.
The VeriSafe™ Absence of Voltage Tester (AVT)

Verifying the absence of voltage is part of the process to automates the voltage verification process and is the
establish an electrically safe work condition (as detailed first AVT tailored for electrical enclosures. This new
in Step 5 of NFPA 70E-2015 Article 120.5 The process typi- technology supports compliance with the latest revision
cally involves using a portable, handheld voltage test of NFPA 70E-2018 Article 120.5
instrument and, to be effective, it is critical to perform
each step of the process in sequence. Additionally, the Register to download the paper:
process requires taking the necessary precautions, such https://pages.panduit.com/verisafe-plantengineering.html
as the proper use of personal protective equipment (PPE).
Injuries from contact with exposed wiring, transformers,

or other electrical components frequently occur in
the workplace and involve construction, installation, cs@panduit.com • www.panduit.com/verisafe

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Digital Engineering Models Enable

Comprehensive Lifecycle Information Management
for Water and Wastewater Treatment Plants
Tony Andrews and Shaun Severin | Bentley Systems, Inc.
Water and wastewater treatment plant design is a large-scale, complex engineering effort
that requires a multi-discipline design team often spread across many offices, and involving
collaboration among different consulting firms, contractors, and owners. Multi-discipline 3D models can
optimize project delivery and improve the management of infrastructure asset information as the project
passes from design into construction and ultimately through to operations.
This white paper demonstrates how the transition to 3D and intelligent multi-discipline models can
empower organizations to capitalize on the use of digital engineering models to establish data integrity
and continuous information flow throughout the lifetime of these assets.
Register to download the paper at: http://bit.ly/2vBLdjm
www.bentley.com
pe201711_whitePprHlf_bentley.indd 1 input #16 at www.plantengineering.com/information 10/17/2017 4:32:05 PM
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Energy Efficiency of Machines:

The Smart Choice of Motorization
Alexandre Perrat | Schneider Electric
Industry and infrastructure consume more than 31% of the available energy in
the world, and electrical motors alone represent more than 60% of that energy
consumption. Designing a more energy efficient machine creates cost savings
over the lifetime of the equipment. This lower cost can then be passed directly
to end users.
This paper compares the technological capabilities and limitations of AC and synchronous motors,
quantifying that a synchronous motor allows up to 20% energy savings while increasing performance.
Register to download the paper:

http://www.plantengineering.com/schneiderelectric-nov17wp
pe201711_whitePprHlf_schneider.indd 1 input #17 at www.plantengineering.com/information 10/23/2017 2:06:43 PM

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SOLUTIONS
SOLUTIONS
COVER STORY Seven tips for proper
bearing maintenance
Capitalize on IIoT to Bearing life can be affected based
on the type of bearing, the load 28
make better decisions they carry and the maintenance
schedule. Properly maintained,
bearing life can be extended and
downtime can be reduced.
Companies are discovering
new solutions to old
challenges through intelligent Industrial energy
web connectivity. This new training and certification
industrial revolution enables
26
On the national and even the
better processing of big data international level, well-structured
for enhanced productivity, training and highly recognized
streamlined operations,
reduced costs, and perhaps
certification programs help develop
a highly skilled and qualified
31
workforce to maintain and improve
most importantly, improved facilities’ energy performance,
safety. particularly as technologies within
these systems become more and
more advanced.
Web Exclusive
A look at energy training programs
The ultimate purpose of training programs is to
provide attendees with skills so that they can
actually operate their equipment and do real
work to improve their systems. Therefore, adding
a field hands-on training component would
significantly increase attendees’ confidence in
applying what they have learned to their own
facilities and thus increase the value of the
training programs.
Go to www.plantengineering.com and review
the specific training programs available.

COVER
STORY
By Matt Puzio, Victaulic
Capitalize on IIoT
to make better decisions
Improved data and analytics offer a greater insight into efficiency.
S
mart technology is an indispensable data exchange built on improved data analytics, better
resource for business competitiveness human-machine interfaces, and advanced production
and growth in the Information Age. It methods. This has the potential to dramatically change
has introduced a new paradigm to the how goods are made.
economic model, changing the way com- Huge advances are being achieved by adapting this
panies operate and invest in business technology for predictive maintenance, enabling com-
development. panies to review sensors and obtain feedback remotely.
Today, digitization is allowing a multitude of devices By communicating with analytic software to interpret
to be connected using communication technologies information, machine tool operators, construction
that produce systems able to monitor, collect, exchange, managers, and manufacturers can make decisions in
and analyze data to deliver valuable insights like never real time and know immediately if they are operating
before. By capitalizing on the Industrial Internet of at peak efficiency. This improved decision-making is
Things (IIoT), companies are finding ways to remove one of the most promising attributes of IIoT.
inefficiencies and use these insights to improve produc- Much can be learned from the productivity gains
tivity, delivering smarter and faster business decisions. manufacturing is experiencing through the application
Manufacturing was among the first business sec- of smart tools and systems.
tors to recognize that leveraging the IIoT and Big
Data could improve productivity by reducing human Manufacturing sector outpaces
error and expediting decision-making. What began as construction industry
a move to manage the risks of cost increases, decreases Some sectors of industry are advancing more rapidly
in profitability, and the persistent fear that jobs would than others in this new ecosystem. A recent McKinsey
be lost overseas became the foundation of progres- & Company report looked at performance in sev-
sive manufacturing that uses eral industries and discovered a noticeable productiv-
M More
SOLUTIONS
smart systems and tools to sig-
nificantly streamline operations
and increase productivity.
ity gap between the manufacturing and construction
industries. In analyzing production data, McKinsey
found that manufacturing has nearly doubled its
Looking for more help with data man- Today, companies are discov- productivity in recent decades while construction
agement? Go to ering new solutions to old chal- productivity has been flat over the same time period.
www.plantengineering.com and lenges through intelligent web While some of this growth can be attributed to
check out these and other stories under connectivity. This new industrial modularity/standardization and minimizing waste
the Keyword: Data Management: revolution enables better process- through the application of lean principles, the success-
Data management is driving the ing of big data for enhanced pro- ful implementation of IIoT is undeniably a significant
IIoT revolution ductivity, streamlined operations, contributor.
reduced costs, and perhaps most Recognizing the successes achieved in manufactur-
The new age of data manage- importantly, improved safety. ing, the construction industry is seeking manufacturing
ment and analysis in the oil and In the age of IIoT, companies companies that are willing to share IIoT experiences
gas industry
are seeing the expansion of auto- and the lessons they have learned. The hope is that by
Big Data: Getting tangible results mated production and increased understanding the successes in manufacturing and

how they were achieved, the construction sector can Personnel using the equipment
achieve similar advances. have confidence in a machine
that provides an accurate groove
Smart technology for pipe fabrication every time. The process delivers
One of the enablers in this new way of working is smart efficiency gains. And quality con-
technology. This is commonly defined as technology trol is built into the tool.
that can adapt automatically and modify behavior to One of the great advancements
fit a particular environment. Using sensors, this tech- to come out of IIoT in manufac-
nology analyzes and infers from collected data and can turing is the development of a
“learn” and adapt to improve performance, in a sense standard, common programming
anticipating and reasoning about what to do next. language—MTConnect—which
Smart technology takes advantage of sensors, data- has enabled communication and
bases, and wireless access to collaborate and improve interoperability across networks.
processes. The result of implementing smart technol- Standardization has not only
ogy is an added level of precision in manufacturing. made the development of smart tools possible, but has Sensor technol-
In the preparation of pipe ends for joining lengths of provided even greater value to the end-user because ogy is enabling
pipe, for example, it now is possible to deliver precision- it can communicate using a universally understood better machine
formed pipe ends using a semi-automated process. language. analytics that will
Integrating IIoT through an intelligent roll grooving help identify and
tool has eliminated the need for measuring and record- Tools enable real-time predict mainte-
ing the specifications of each individual groove. The eemote troubleshooting nance issues. All
previous extent of fine tuning and adjustment has been Smart technology also is being used to improve opera- images courtesy:
removed from the process, allowing a machine operator tional uptime, by allowing for real-time troubleshoot- Victaulic
to complete the procedure without interruption. IIoT ing on the shop floor, truly one of the game-changers
has helped to reduce risk and produce an end product emerging from IIoT. If technical difficulties occur in
that is certified to the specifications. the shop, the operator can speak to a team of special-
With this approach, a machine operator introduces ists to discuss and help solve the issue as it arises. Any
size change through intelligent technology. Now, simply equipment that is connected to the Internet can be
hitting a button initiates the change instead of manually serviced by technicians from anywhere in the world.
measuring and adjusting the size. Sensor data transmitted and stored in the cloud allow
Smart technology delivers a significant change to a manufacturer with access to evaluate the performance
manufacturing by efficiently gathering, tracking, and data of a piece of equipment, tool, or product and to
managing data. Taking grooved pipe end preparation run diagnostics remotely. The results can be used to
again as an example, while the grooving data from perform predictive maintenance, adjust for improved
the tool was collected previously, it was not optimized productivity, or identify components that require soft-
efficiently. Either a voluminous amount of data was ware updates.
collected but not used because it was labor intensive The level of customer service that can be provided
and time consuming to interpret, or data about every on tools produced this way is leaps and bounds ahead
project, every piece of pipe, every size, and every groove of customer service provided for traditionally manu-
was measured and tracked manually, creating a lengthy factured parts and equipment.
process with considerable potential for the introduction
of human error that generated data that was difficult Increased safety
to manipulate and manage. with proximity scanners
The time it takes to record groove dimensions Manufacturing, fabrication environments, and job sites
manually is significant, and tracking the data once are very much the same when it comes to safety. The
it is recorded so it can be used when it is needed is slightest mishap can lead to work stoppage or worse.
next to impossible. Using the IIoT has allowed that New technology answers the call for increased worker
step to be eliminated completely. Now, a roll grooving safety as much as it does for creating a more stream-
tool records dimensions automatically and transmits lined, efficient workplace.
data from the tool either through email or each tool’s Smart technology has opened the door for some
secure web server. advanced safety features, such as proximity scanners

SOLUTIONS
By Nancy Ross, Bearing Boys Ltd.
Seven tips for proper

bearing maintenance
Load, use are keys to ensure longer operational life.
B
earings play a significant role in the free 1. Handle with care
and unrestricted movement of mechanical Bearings are delicate and can get damaged quickly.
parts or components, from car wheels to As such, they should be stored horizontally in a clean
skateboards as well as many other things. and dry environment with their packaging intact. Do
Bearings accept the weight of the load and make things not expose them to airborne contaminants, as even a
move without any or with much less friction. In a world tiny speck of dirt can cause premature failure. Never
without bearings, mechanically moving parts would hammer or pound them, or apply a direct force on
malfunction and stick, preventing smooth operation. them or their outer ring, which can damage the roll-
Bearing life can be affected based on the type of bearing elements, resulting in misalignment. The most
ing, the load they carry and the maintenance schedule. important thing to remember is to never remove
Properly maintained, bearing life can be extended and bearings from their packaging until ready for use.
downtime can be reduced.
2. Check the bearing housing and shaft
Here are seven tips for bearing maintenance to help It is crucial that the housing and shaft are inspected
ensure a longer lifespan. for defects or damage. Always use a soft cloth to
Poor lubrication practices account for upwards of 40% of

bearing failures. There’s no excuse for over or under-greasing
your bearings! Improve reliability and save money with our
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clean the surfaces and make sure any nicks ing fitting tool kits, oil injector kits, hydraulic
and burrs are removed. nuts, or induction heaters should be used in the
mounting and dismounting processes. These
3. Mount the bearings correctly tools ensure the smooth process of mounting or
The method used to mount the bearings dismounting, to minimize the risk of damage.
depends on the type of bearing. For example,
bearings with cylindrical bores generally are 6. Avoid corrosion
mounted through a press fit method. Bearings It is crucial that you should not expose bearings to
with tapered bores can be mounted directly the presence of water for a long time, as it will lead
on tapered or cylindrical shafts with the use of to rust and corrosion. It also will cause the pre-
tapered sleeves. However, pressure should be mature failure of the bearings, which can affect
applied only with a press fit because without it the machine performance and productivity. As a
the raceways can become damaged. result, it will increase operating costs. Also, make
sure to wear gloves when handling bearings.
4. Avoid preheating or overheating Perspiration also can lead to rust and corrosion.
The maximum heating allowed on the bearings
depends on the heat treatment of the material. 7. Lubricate properly
If they are heated above the permitted limit, If you want to prolong the life of your bear-
they can permanently deform or soften the ings, it is crucial that they should be lubricated
bearing steel, lowering load carrying capacity properly. The correct lubricant depends on the
and resulting in a failure. Always heat the bear- environmental conditions, temperature, speed,
ings using induction heaters, and never with an and load. In this case, it is advisable that you
open flame. should follow your manufacturer’s recommen-
dations. PE
5. Always use the proper tools
Specialized tools like bearing pullers, bear- Nancy Ross is with Bearing Boys Ltd.
Introducing the
Machining System
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• The industry’s first “Zero Pinch Point” OD mounted split-frame pipe lathe
• Revolutionary, patented high-speed ball bearing system
• Faster cutting speed, better surface finishes, and longer bit life
• Rigid, high-stability frame for unlimited machining applications and accessories
With productivity, reliability and system expandability

like this, TRIMAX will save you a fortune!
See the future of portable machining at Booth 5615,
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©2017
COVER
STORY
that can automatically stop a machine when they sense of data errors by successfully combining a focus on
someone has entered the work area. They also prevent people, process, and technology.
accidental startups. This is one of the improvements A once manual process, susceptible to human error,
that has new smart roll groovers outfitted with these now streamlines through automation. This in turn
proximity scanners which can be customized to should reduce data errors, rework, and risk while
the shop environment. improving productivity. By ensuring that people
understand the data, the guidelines to follow, and how
Improving the mechanical to improve data quality, organizations can reduce data
process with automation errors and gain a competitive advantage.
Automation control technology is key to suc- Intelligent technology rapidly is becoming the
ceeding in the machinery sector. Big Data and norm rather than the exception in transportation,
analytics are being adopted across industries, the automotive industry, retail and residential build-
including in the manufacturing of piping sys- ings, manufacturing, agriculture, and medicine. But
tems. none could benefit more quickly and significantly
Mistakes from human errors have been than construction. Innovative systems and tools that
reduced drastically through the implementa- today are capitalizing on the power of the IIoT in
tion of IIoT, which can facilitate risk reduction manufacturing hold the key to unlocking transfor-
mational gains in productivity, safety, and efficiency
Smart technology also is being used to for the global construction industry. PE
improve operational uptime, by allow-
ing for real-time troubleshooting on the Matt Puzio is technical leader in the tool tech-
shop floor. nology department at Victaulic.
HD ENV - A NEW ERA IN VIBRATION MONITORING

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SOLUTIONS
By Wei Guo, Thomas Wenning, Sachin Nimbalkar, Daryl Cox and Kiran Thirumaran, Oak Ridge National
Laboratory, and Sandy Glatt, U.S. Department of Energy
Industrial energy training

and certification
Oak Ridge report details how to find, use industry resources.
T
he major industrial energy systems particularly as technologies within these systems
commonly found in manufactur- become more and more advanced.
ing facilities are compressed air, A review of vendor-agnostic training and certi-
ammonia refrigeration, chilled fication programs concludes:
water, steam, process heating,
combined heat and power, pumps, • Most training programs focus on operations,
and fans. The efficiency of these systems contrib- maintenance, safety, and design, though some
utes significantly to the whole-facility energy per- briefly touch on energy performance aspects.
formance. On the national and even the interna-
tional level, well-structured training and highly • The Certified Refrigeration Energy Specialist
recognized certification programs help develop a certification by the Refrigerating Engineers and
Image courtesy: highly skilled and qualified workforce to main- Technicians Association (RETA) and Pump Sys-
CFE Media tain and improve facilities’ energy performance, tem Assessment Professional certification by

SOLUTIONS
the Hydraulic Institute (HI) were • Developing energ y efficiency- In the United States, industrial facil-
the only certifications found to focused training and American ities accounted for about 32% of the
be tool-agnostics and emphasize National Standards Institute (ANSI) total national energy consumption in
knowledge and skills for improv- accredited certification programs 2016. Improving the energy efficiency
ing and maintaining systems energy for industrial energy systems will of industrial facilities benefits com-
performance. fill the gap between market needs panies financially, mitigates energy-
and currently available programs. related business risks, and protects the
environment by reducing greenhouse
gas emissions.
Well-structured training programs
enhance the attendees’ understanding
of working principles, knowledge of
best practices, and capability to ana-
lyze the energy performance data of
industrial energy systems. Training
employees on these systems also helps
create a safer working environment,
increases employee’s engagement and
productivity, and improves system
reliability and energy efficiency.
Certifications make the capabili-
ties of industrial professionals more
visible. Certification programs also
motivate professionals to strategically
improve their expertise and obtain
new skill sets. In addition, highly cred-
ible certification programs provide
employers with a reliable mechanism
for evaluating the technical compe-
tence of candidates for positions that
helps them hire the right people.
Energy efficiency-focused certifica-
tion programs for industrial energy
systems are needed. Such certifications
would enable engineers to more objec-
tively demonstrate their competence
on these systems. On the national
M More
SOLUTIONS
Go to www.plantengineering.com
and enter the Keyword: Energy
Management to review our exten-
sive coverage of energy manage-
ment.
Implementing energy manage-
ment for machinery and process-
ing plants
Making the case for energy man-
agement technology
Getting to the core of energy
management.
32 • November 2017
“Well-structured training programs enhance the attendees’ understanding of
working principles, knowledge of best practices, and capability to analyze the
energy performance data of industrial energy systems. Training employees on these
systems also helps create a safer working environment. ”
level, they would help in developing a
more qualified and stronger workforce
that would continuously improve the
energy efficiency of industrial facili-
ties.
Air-Driven Power
ANSI accreditation for personnel
certification agencies ensures that the
operation of these agencies conforms
Meets Results.
to the requirements of the Interna-
tional Standards ANSI/ISO/IEC 17024
Conformity Assessment—General
Guaranteed.
NEW Model 15 Industrial Air-Vac offers 15 gallons of cleaning
Requirements for Bodies Operating capacity for powders & combustible dusts, running only on
Certification of Persons. The ANSI compressed-air, No Electricity Required! With its uniquely
accreditation is recognized nation- portable design, 99% filter efficiency rating, noise levels
below OSHA standards, and a performance guarantee, the
ally and internationally. To ensure MDL15 is more than an industrial vac; it’s a business asset.
these certifications are designed and
• VAC-U-MAX Single-Venturi Power Unit:
executed based on high and consistent Adjustable for “Double-the-Vacuum” Power
standards and are internationally rec- • PTFE Pre-Filter & Secondary Cartridge Filter
ognized, it might be worth consider- • Suction Power: 16” Hg (208” H2O)
• “Off-the-Shelf” Static-Conductive Polybags
ing having all certification programs • Anti-Sparking 304 & 316 Stainless Steel
focused on energy efficiency be ANSI- • Lowest Compressed-Air Consumption Available
• Complete Tool Kit for Floors Walls,
accredited. Doing so could result in Machinery & Overhead Surfaces
these certifications being adopted by • Quiet!
other countries and would advance
the development of a highly skilled
industrial energy system workforce
internationally.
Current training
and certification programs
Compressed air system PREVIEW VIDEO!
The Compressed Air Challenge Visit vac-u-max.com/MDL15
(CAC) and Compressed Air and Gas (800) VAC-U-MAX
Institute (CAGI) are two major non-
profit trade associations that provide
training. CAC currently offers four
training programs: Fundamentals of
Compressed Air Systems, Advanced
Management of Compressed Air Sys-
tems, AirMaster+ Specialist Qualifi-
cation (in partnership with the U.S.
Department of Energy (DOE)), and
“Compressed Air, It’s Not Free!”.
CAGI’s training program, called
“Smart Site,” is a series of eight online
e-learning modules covering various
aspects of compressed air system oper- WET/DRY • AIR OPERATED AND ELECTRIC DRUM-TOP • CONTINUOUS DUTY • COMBUSTIBLE DUST
CENTRAL SYSTEMS • CONTINUOUS-BAGGING • LIQUID & SLUDGE • FLAMMABLE LIQUIDS
ation and maintenance. DOE offers SUBMERGED RECOVERY • METALWORKING • PHARMACEUTICAL • STEEL SHOT
INTERCEPT HOPPERS & PRE-SEPARATORS • HSE / INDUSTRIAL HYGIENE SOLUTIONS
November 2017 • 33
SOLUTIONS
hands-on and classroom training on general compressed air system knowl- One online education provider,
compressed air system optimization edge and their products and services. PDHonline.com, offers seven online
through the Better Plants program’s Typically, these training sessions can be courses for compressed air systems:
In-Plant Trainings. tailored to meet clients’ specific needs. C ompressed Air Energ y Storage,
Some air compressor system manu- Limited information was available C ompressed Air Systems, Intro-
facturers and vendors provide train- regarding the details of the training duction to Industrial Compressed
ing sessions to educate their clients on content. Air Systems, Improving the Perfor-
mance of Compressed Air Systems,
Compressed Air Energy Efficiency,
Air Compressors—Basic Concepts
and Application, and Introduction
to Compressed Air Systems. The
detailed content of the courses is
not accessible without registration
for the courses.
Only one certification was found
for compressed air systems—Quali-
fied AIRMaster+ Specialist, which is
offered by CAC and DOE. This cer-
tification recognizes candidates for
their ability to use the AIRMaster+
software effectively with industrial
end use equipment. Candidates for
certification must pass an exam,
which includes both written and
practical components.
In summary, not including train-
ing provided by manufacturers or
vendors, 12 training programs and
courses were found. Only two online
courses seemed designed to focus on
the energy efficiency perspective of
compressed air systems. The only
certification found was Qualified
AIRMaster+ Specialist, and it is not
accredited by the American National
Standards Institute (ANSI).
Ammonia refrigeration system

Four community colleges (Garden
City Community College, Lanier
Technical College, Polk State College,
and Industrial Refrigeration Techni-
PRUFTECHNIK is a leading single-source solution provider for machine cal College) and three engineering
laser alignment, condition monitoring and nondestructive testing. consulting/training firms (Nh3Jobs
PRUFTECHNIK’s technical innovations optimize the availability of your Training, Industrial Consultants,
and Envirosure Solutions) seem to
production assets—and stop small amounts weighing heavily on your be the major training providers. The
bottom line. training programs offered by these
providers are structured mainly to
www.pruftechnik.us help prepare participants to become
ammonia system operators and ener-
gy specialists certified by RETA. Most
of the courses have both classroom
and field training components. They
include a basic introduction to indus-
input #24 at www.plantengineering.com/information 34 t November 2017

THE
WORLD’S
LARGEST
Web Exclusives
Go to www.plantengineering.com, Keyword: Oak
Ridge energy to find tables and resources on specific
SELECTION
energy training programs and federal resources to help
you find and evaluate training.
OF STOCK
trial refrigeration systems, industrial refrigeration sys-
tem operation, process hazards and safety, and energy
efficiency.
SPRINGS
The Department of Engineering Professional Develop-
ment at the University of Wisconsin–Madison provides
a set of courses covering the basics, principles, design,
safety, and hazard analysis of industrial refrigeration
systems. DOE offers hands-on and classroom training
on ammonia refrigeration system optimization through
the Better Plants program’s In-Plant Trainings.
Some manufacturers and vendors also provide train-
ing on refrigeration systems and their products. Limited
information was available on the details of the training
content.
RETA provides four certifications: Certified Assistant
Refrigeration Operator (CARO), Certified Industrial
Refrigeration Operator (CIRO), Certified Refrigera-
tion Energy Specialist (CRES), and RETA Authorized
Instructor (RAI). Note that CARO and CIRO are ANSI-
accredited, and candidates for these two certificates must
pass exams with both written and practical components.
CRES and RAI are not ANSI-accredited.
The International Institute of Ammonia Refrigeration
(IIAR) provides a certification for Safe Design of Closed- •
Circuit Ammonia Refrigeration Systems.
In summary, not including training provided by manu- •
facturers or vendors, 48 training programs and courses
were found. Three of those training programs focus on •
the energy efficiency of ammonia refrigeration systems.
Five ammonia refrigeration system-related certifications • on in-stock parts*
were found, two of which are ANSI-accredited. One of
the five certifications is for energy efficiency; it is not • on demand
ANSI-accredited.
• with competitor
Chilled water system
The main providers of training in chilled water systems part numbers
are the American Society of Heating, Refrigerating and
Air-Conditioning Engineers (ASHRAE), the University
of Wisconsin–Madison, Northwest Energy Efficiency
Alliance, and a few training companies. Major chiller
MADE IN USA
manufacturers also offer training. Most training pro-
grams are focused primarily on the design of chilled
water systems. 800-237-5225
Not including the training provided by manufactur- ISO 9001:2008
ers or vendors, 12 training programs were found, two www.centuryspring.com
of which (provided by Northwest Energy Efficiency *Order must be placed by noon PST
Alliance) focus on energy efficiency. No chilled water input #25 at www.plantengineering.com/information
PLANT ENGINEERING November 2017 • 35 Don’t see what you’re looking for?
Contact our Custom Department.
SOLUTIONS
system-related certifications—focused process heating system optimization ited detailed information regarding
on either design, operation, or energy through the Better Plants program’s the content of the training.
efficiency—were found. In-Plant Trainings. Two certifications were found:
Numerous engineering consulting Qualified Process Heating Assessment
Process heating system firms also provide training in process and Survey Tool Specialist, available
The Industrial Heating Equipment heating energy assessment and burner but no longer actively offered by DOE,
Association (IHEA) and Gas Technol- operation. Their websites offer lim- and Chartered Industrial Gas Consul-
ogy Institute (GTI) are the tant, offered by GTI.
two major nonprofit trade
associations that provide
training in process heating. By The Steam system
GTI has a two-day course to provide
Two training programs pro-
vided by IHEA are focused
NUMBERS an essential understanding of com-
plex industrial steam generation and
32%
on t he f u nd ame nt a ls of in-plant distribution. The American
pro cess he at ing and t he S ociety of Mechanical Engineers
understanding of various (ASME) has a two-day course focusing
industrial process heating on boiler operation and maintenance.
technologies, whereas the Percentage of total energy DOE offers hands-on and classroom
two training courses pro- use consumed by industrial training on steam system optimization
vided by GTI concentrate through the Better Plants program’s
more on the energ y effi- facilities in 2016. In-Plant Trainings.
ciency of new and existing Source: Oak Ridge National Numerous training programs are
process heating technolo- provided by steam system manufac-
Laboratory data
gies. DOE offers hands-on turers and vendors of steam systems,
and classroom training on and some of them focus on system
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“Energy efficiency-focused certification programs for industrial energy
systems are needed… On the national level, they would help in developing
a more qualified and stronger workforce that would continuously improve the
energy efficiency of industrial facilities. ”
optimization. However, the techni- Combined heat and power system tion Certified Professional training
cal depth of those programs usually The Association of Energy Engi- provided by AEE.
cannot be easily ascertained from neers (AEE) and ASHRAE are the
the training information on their two major combined heat and power Pump system
websites. (CHP) system training providers. Numerous pump training programs
Only two certifications for steam These workshops mainly cover the were found. Most of these programs
systems were found: Qualified Steam design, operation, and maintenance are provided by pump manufactur-
System Assessment Tool Special- of CHP systems. Three training ers and vendors and focus on various
ist, available but no longer actively programs were found, not including aspects of pump systems: the basics of
offered by DOE, and ATMT Certified training provided by manufacturers hydraulic systems, pump components
Qualified Boiler Operator, offered by or vendors. (e.g., seals, drive, lubrication, vibra-
TPC Trainco. The only CHP-related certification), installation, operation, and
tion found was Distributed Genera- maintenance. DOE offers hands-on
CFE Media’s
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SOLUTIONS
and classroom training on pump sys- tenance of fan systems. DOE offers programs briefly discuss the
tem optimization through the Better hands-on and classroom training on energy performance aspects of
Plants program’s In-Plant Trainings. fan system optimization through the these systems.
The only nonprofit trade association Better Plants program’s In-Plant Train-
training provider found was Hydrau- ings. One energy consulting firm was 2. Based on course titles, several
lic Institute (HI). HI provides three found to provide online courses focus- training programs may focus
major training programs: Pump Sys- ing on fan system energy efficiency. No on optimizing system energy
tems Assessment Certificate Training nonprofit trade association training efficiency ; however, limited
Program, Rotodynamic Pumps Cer- providers for fan systems were found. content information could be
tificate Training Program, and Posi- found to evaluate those train-
tive Displacement Pumps Certificate Six conclusions ing programs.
Training Program. on energy training
HI currently offers the Pump System There is a need to improve training 3. Qualified System Assessment
Assessment Professional (PSAP) certi- and certification programs for those Tool Specialist courses, which
fication. This certification is intended operating these energy systems as well are available but no longer
to be ANSI-accredited. DOE makes as to make such programs more widely actively offered by DOE, cover
available a certification for Qualified available. This study reached the fol- five systems (process heat-
Pumping System Assessment Tool Spe- lowing conclusions: ing, steam, pump, fan, and
cialist but no longer actively offers it. compressed air) and are heav-
1. There are a great number of train- ily focused on the use of DOE
Fan system ing programs for each industrial software tools. The DOE does
Like the case for pump systems, a energy system. Most training provide In-Plant Trainings
large number of manufacturers and programs focus more on opera- which consists of hands-on and
vendors provide training programs for tions, maintenance, safety, and classroom training through the
the installation, operation, and main- design; however, some of these Better Plants program; however,
this training does not provide
certification.
4. The only programs that focus

on tool-agnostic knowledge and
skills for improving and main-
taining energy performance are
The MD III™ System includes CRES by RETA and PSAP Certi-
all you need for complete fication by HI. Only CARO and
Energized and De-Energized CIRO by RETA are ANSI-accred-
Testing of Motors, ited. PSAP by HI is intended to
Generators & Transformers be ANSI-accredited.
Combine the power of Motor
Circuit Analysis (MCA™) and 5. Developing energy efficiency
Electrical Signature Analysis focused training programs that
(ESA) to evaluate and trend your provide a reasonable level of
entire motor system
technical depth, hands-on field
Auto diagnosis within instrument
providing an immediate health training, and easily accessible
status report information about the content
Route-based testing and trending – would fill the gap between mar-
ideal for Predictive Maintenance ket needs and currently available
Reports provide indication of programs.
early winding faults, rotor
Excellent Post-Sale problems, incoming power
Service and Support
issues, electrical and 6. ANSI-accredited certification
Worldwide Training –
Earn CEUs / IACET Accredited
mechanical motor condition and programs focusing on the energy
driven load mechanical condition
efficiency of industrial energy
systems would help in develop-
Finally – Predictive ing a more qualified and stron-
Motor Maintenance Made
VERY Easy! ger national and international
Testers The ideal instruments for troubleshooting, quality
control and predictive maintenance of electric
workforce. PE
www.alltestpro.com motors, transformers and generators.
38 • November 2017
INNOVATIONS
2017
41
PRODUCT Year FINALISTS
of the
I
t’s been 30 years since Plant Engineering first intro- ation this year represent the best efforts of product managers
duced Product of the Year, and it’s remarkable how and innovators around the world. They’ve spent years talk-
many of the great innovations in the 2017 edition are ing to plant managers like yourself, reviewing the needs of
improvements on products from the past. A review manufacturing and then putting their product development
of the 2002 Product of the Year finalists and those teams on the trail of ways to make their great products just
from this year find that fuses, voltage testers, lower-wattage a little better.
lighting and flow controls can be found in both listings.
And yet there is much that has changed. For Now it’s your turn. The other aspect of Product
one thing, there was no Automation & Con- of the Year that makes it such a sought-after award
trols category in 2002, and there was no Asset is that selecting the winners are your responsibility.
Management category, let alone a Maintenance Because each year’s Gold, Silver and Bronze win-
Software category. We added a Safety category ners in each category are selected by qualified sub-
more than a decade ago to bring more attention scribers to Plant Engineering, we can confidently
to this critical area of plant operations. say that this is the best award in manufacturing.
Taken individually, each of this year’s 102 The awards are won by the individual suppliers,
Product of the Year finalists offer a unique but the awards themselves belong to our readers.
solution to a specific problem. In some cases, Each year, we ask you to consider these entries,
that improvement is incremental, but then, so and I’m happy to say that each year, you get it right.
is the entire concept of improvement. Process And we ask you to do it again this year. The
improvement is, by definition, a process; manu- voting ballot for Product of the Year is now live
facturers are looking for ways to get a little better at www.plantengineering.com/NP4E along with
every day. the link to each of this year’s products. Each vote
What Product of the Year offers each year is screened to make sure only qualified readers
is a way to identify in one place all the ways to vote on these product categories. This ensures the
improve operations. Not every product fits every integrity of the contest; it also lets both our sup-
plant application, but what we also hope Product pliers and our readers know that when the awards
of the Year does each year is expose readers are handed out in April 2018, they represent the
to think about how each of these categories best insight from our readers.
impact their operations. As it has been for 30 years, Product of the Year
There are 15 categories this year; in 2018, is a three-step process: Review the entries. Cast
we’ll add robotics as a category to identify your votes. Think about your manufacturing
another area of plant operations getting a lot of plant and ways new products can lead to process
attention. The products you’ll find for consider- improvement.
By Bob Vavra, Content Manager, and Amanda Pelliccione, Project Manager

The 1st micro PLC
with a can-do attitude
2017
Stand-alone PLC Unit Expansion Modules
The new BRX Micro PLCs are determined to get it done!

The new BRX PLC family incorporates many high-level features in a small, solid
package - allowing it to stand strong no matter the challenge. Loaded with
options and using the very popular Do-more! DM1 technology as its engine,
this micro controller packs a big punch for a little price!
Starting at CPU and I/O

AutomationDirect Allen-Bradley Siemens IDEC
$199.00
BRX PLC Micro 800 S7-1200 FC6A
Comparison
PLC Unit
(with Ethernet)
$473.00 $642.00 $814.00 $550.00
BX-DM1E-36ED13-D 2080-LC50-48QVB 6ES7 214-1AG31-0XB0 FC6A-C40K1CE
(BX-DM1-10AR-D) $38.00 $443.00 $95.00

(28) 24VDC Inputs Built-in
with 10 built-in discrete I/O BX-08ND3
(8-pt DC IN module + 20 DC IN on PLC unit)
(28 DC IN on PLC unit)
6ES7 221-1BH30-0XB0
FC6A-N08B1
The BRX PLC family offers: (20) 24VDC Outputs

$45.00 Built-in $443.00 $140.00
BX-08TD1 (20 DC OUT on PLC unit) 6ES7 222-1BH30-0XB0 FC6A-T08K1
(8-pt DC OUT module + 16 DC OUT on PLC unit) (16-pt DC OUT module + 10 DC OUT on PLC unit) (8-pt DC OUT module + 16 DC OUT on PLC unit)
• Advanced motion control (4) Analog Inputs Built-in $149.00

(4 Analog IN on PLC unit) 2080-IF4
$330.00 $359.00
• Robust data logging 6ES7 234-4HE30-0XB0 FC6A-L06A1
(2) Analog Outputs Built-in $89.00 (4IN/2OUT Analog combination module) (4IN/2OUT Analog combination module)
• Onboard serial and Ethernet ports

(2 Analog OUT on PLC unit) 2080-OF2
• Discrete, high-speed and

Total System Price $556.00 $880.00 $2,030.00 $1,144.00
analog I/O All prices are U.S. published prices. AutomationDirect prices as of 7/15/2017. Allen-Bradley, Siemens and IDEC prices taken from www.radwell.com 7/15/2017.
• Expansion capabilities
• Interchangeable
communications port
• Free programming software
(with simulator)
• Integrated video help
• Free technical support Research, price, buy at:
• Much, much more...
www.BRXPLC.com
Order Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2017 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation

INNOVATIONS
Asset Management
Asset health application Mobile-friendly asset manager
Plantweb Insight is a family of operational excellence AMS Device Manager helps avoid unnecessary down-
applications for monitoring the health of steam traps, time with a window into the health of intelligent field
pumps, heat exchangers, and other plant assets. Plantweb devices. It provides maintenance and operations per-
Insight strategically interprets sonnel the ability to work smarter. Based on real-time
plant data to provide person- condition data from intelligent field devices, plant staff
nel with actionable information. can respond quickly and
The intuitive, browser-based make informed decisions
user interface enables quick and on whether to maintain
informed decisions to ensure or replace field devices.
reliability, improve safety, and Equipped with AMS Device
reduce energy use. Abnormal situations and predictive View, this software extends
diagnostics are presented to personnel in real-time, elimi- asset management capa-
nating the need for manual calculations or periodic data bilities to anywhere with an internet connection through
collection. mobile-friendly dashboards.
Emerson Automation Solutions Emerson Electric Co.
www2.emersonprocess.com www.emerson.com
Wireless accelerometer
Prognostic service The third generation GTI-220 is a 2-axis wireless accel-
erometer that contains an internal biaxial sensor with an
Guardian Support is a prognostic service designed to
external channel to connect a tachometer for balancing
optimize reliability and performance of automation sys-
applications or an additional
tems and improve competitive advantage through critical
sensor for phase measure-
service and support information. The service can help
ment. Pairing the GTI-220 with
improve productivity by analyzing data and delivering
VibePro 8 creates a powerful
useful, relevant, critical, real-time, system-specific informa-
predictive maintenance sys-
tion to keep plants current. By making day-to-day systems
tem. VibePro software offers
management tasks fast and efficient, Guardian Support
solutions for vibration analysis,
can also reduce operations and maintenance costs by
dynamic balancing, infrared
shifting from a reactive/preventive maintenance strategy
thermography, and shaft laser alignment on a single
to a predictive strategy.
device. The software communicates directly to the align-
Emerson Electric Co.
ment component of the GTI-220.
www.emerson.com
GTI Predictive Technology Inc.
www.gtipredictive.com
Fleet asset manager Enterprise asset manager

Infor EAM Mobile for Fleet allows fleet organizations to Infor Enterprise Asset Management (EAM) is a software
perform functions such as equipment solution with built-in functionality, the flexibility to inte-
management, work management, grate with other applications and is highly configurable
materials management, inspections, while still being able to
checklist, and asset inventory. Tech- meet users’ needs right
nicians working remotely can now out of the box. Version
access, capture, and manage informa- 11.3 is designed to support
tion from the job site. The applica- mobile, transit, and cloud
tion can operate in a disconnected technologies. Infor EAM
mode allowing users to create and version 11.3 enables users
modify data when a data connection to track and record inci-
is not available. Once the device re- dents that fall outside the
establishes a connection, the newly normal work order process and streamline the difficult
gathered data can be accessed and modified. task of uniformly ranking equipment.
Infor Infor
www.infor.com www.infor.com

INNOVATIONS
Asset Management Automation & Controls
Spill risk algorithm Compact PLC
The patent-pending PIG Spill Risk Algorithm performs The compact BRX programmable logic controller (PLC)
more than 600 physics-driven calculations to each liquid features built-in data log-
area to help facilities understand ging, motion control, serial
their own specific spill risks and and Ethernet communica-
the steps necessary to reduce tion, an interchangeable
risk. The algorithm asks six simple (hot-swappable) communi-
questions per area and takes less cations port, and integrated
than 3 minutes per area to gather high-speed I/O. Support for
data. A comprehensive report EtherNet/IP, Modbus RTU
includes a view of spill risks across and TCP, ASCII, and custom protocols also is included.
an entire facility and exact steps The BRX requires no base or backplane, and the unit can
to take to aid in compliance. be expanded with up to eight additional I/O modules.
New Pig The stackable design of the BRX allows users to purchase
www.newpig.com only the I/O required for their particular application.
AutomationDirect
www.automationdirect.com
Device health software IoT connection app

FactoryTalk Analytics for Devices provides health and The IoT Gateway makes it easy to connect to the Internet
diagnostic analytics from industrial devices. It crawls indus- of Things (IoT) and Industrie 4.0 environments without
trial networks, discovers assets, and provides analytics intervening with automation logic. The precisely coor-
by transforming the data dinated combination of control hardware and software
generated into preconfig- designed for implementing IT applications collects
ured health and diagnostic sensor and process
dashboards. The system data, transmits it to the
also delivers “action cards” manufacturing execution
to smartphones or tablets system, cloud applica-
if a device requires atten- tions, or local machine
tion. As the application state monitoring systems
uncovers information about how the devices are related to and enables process data
each other it starts to understand the system on which it is analysis. The IoT Gateway is a path to bringing legacy
deployed to make prescriptive recommendations. machinery into the digital age.
Rockwell Automation Bosch Rexroth
www.rockwellautomation.com www.boschrexroth-us.com
Asset management app Mobile operations viewer

FactoryTalk TeamONE is a smartphone application that DeltaV Mobile delivers an entirely new operational expe-
seamlessly connects to the technology that manufacturers rience and empowers teams to improve operations per-
adopt during their digital transformation. The app boosts formance and safety by having
team productivity by enabling users to collaborate and the plant at their fingertips virtu-
share knowledge, ally anywhere. DeltaV distributed
view live production control system users can know
diagnostics, inter- the health of their operations
act with machine on-demand by viewing real-time
alarms, and trouble- process values, trends, alarms,
shoot devices. historians, and other key data
TeamONE is designed for hybrid connected industrial from their mobile devices. Col-
environments and can be downloaded, installed, and laborative features make it easier to streamline workflows
used right away by anyone on any company or personally by making it easier for managers and engineers to share
owned iOS and Android smartphones. critical information for enhanced business results.
Rockwell Automation Emerson Electric Co.
www.rockwellautomation.com www.emerson.com

Downtime is
a dirty word
Equipment failure–detrimental to any business–is especially catastrophic for manufacturers.

Unexpected downtime cascades through the entire production cycle, causing delays to order
fulfillment and delivery. Asset managers who need to keep their equipment performing no
matter what rely on Infor EAM to improve asset performance and minimize risk.
Thank you to our customers for voting for Infor EAM in Plant Engineering’s
Product of the Year awards.
infor.com/eam
800.260.2640
eam@infor.com 2017
Copyright ©2017 Infor. www.infor.com. All rights reserved.

INNOVATIONS
Automation & Controls
Radar level instrument Cabinet cooler
The 80 GHz Micropilot FMR6x free space radar level The 316SS Cabinet Cooler incorporates a vortex tube
instrument is suitable for use in tanks or silos with com- to produce cold air from compressed air with no mov-
plex geometries, obstacles, ing parts. The compact cabinet cooler can be installed
baffles, and/or nozzles. Its small in minutes through a standard electrical knockout. The
beam angle of only 3 degrees NEMA 12 (IP54) cabinet cool-
and focused FMCW 80 GHz er (dust-tight, oil-tight) is ideal
signal beam provides level for general industrial environ-
measurement at distances up to ments where no liquids or
410 ft with accuracy to ±1 mm. corrosives are present. The
Advantages of the 80 GHz signal cabinet cooler is available
include reduced tank wall effects, in many cooling capacities
less interference from obstacles, for large and small control
and the ability to work with lower panels. Digital electronic temperature control provides
dielectric media. precise temperature control for electrical enclosures.
Endress+Hauser Exair
http://us.endress.com www.exair.com
Master message controller IIoT, Wi-Fi ready PLC

The EZ iMarquee is an all-in-one master message control- The EZLogix auto-
ler and LED message display. Combined with EZ iMar- mation control-
quee Editor software, users ler is a low cost,
can easily and quickly display advanced PLC that
valuable machine or plant data is Industrial Internet
coming from a PLC or supervi- of Things (IIoT) and
sory control and data acquisi- Wi-Fi ready, has
tion (SCADA), on the intelligent USB data logging up to 64 GB, programming software
marquee, without the need to and simulator package, and more. It is a rugged modu-
write or change any PLC ladder lar rack din-rail or panel-mount PLC with an integrated
logic. The EZ iMarquee comes message queuing telemetry transport (MQTT) protocol,
in various sizes ranging from 2 lines 10 characters to 4 lines direct connectivity to external devices (such as sensors
40 characters. and analog inputs), and easy-to-setup secure communi-
EZAutomation cation with other networks.
www.ezautomation.net EZAutomation
www.ezautomation.net
Modular HMI, PLC unit Quick connectors

EZTouch I/O Flex is a powerful, modular, all-in-one human- The SMART FE and FI Series quick connectors—enabled
machine interface (HMI) and PLC unit that can act as a with Connection Verification technology—use an
stand-alone machine controller or smart HMI with local embedded, high-resolution sensor to signal when the
I/O for existing PLCs. The compact, touchscreen controller connector has properly
saves space, time, and money actuated. The unique tech-
for various control applications. nology improves leak test-
Flexible I/O modules include ing efficiency by reducing
ac inputs/outputs, dc inputs/ the number of failed tests
outputs, relay outputs, volt- due to improper connec-
age and current analog I/O, tions caused by a variety of
thermocouple and RTD inputs, common problems, includ-
high-speed counter inputs, ing operator placement and worn seals. Connection
pulse width modulation for Verification technology improves safety and efficiency in
motion control and more. automated, semi-automated or manual leak test stations.
EZAutomation FasTest Inc.
www.ezautomation.net www.fastestinc.com

INNOVATIONS
Hazardous location HVAC controller
enclosure cooler The PowerGate H heating, ventilation, and air condi-
The ProtEX Vortex A/C cooler is tioning (HVAC) controller offers the
certified to the latest EN ISO 80079- simplicity and functionality of an HVAC
36:2016 standard and offers 900, 1500, bypass controller and the high specifi-
2500, or 5000 BTU/h cooling capacity cation, performance, and reliability of
to suit the differing needs of enclo- the FR-F800 variable frequency drive
sures and facilities. The unit operates (VFD). The Slimline enclosure is ideal
in environments up to 175°F and is for mounting in areas where space is
designed to cool enclosures quietly, limited. PowerGate H is fully compatible
rather than adding to industrial noise, with earlier generations of Mitsubishi
with 62 dBA operation, 78% quieter Electric controllers and offers signifi-
than typical vortex coolers. The unit’s design ensures that cant product advantages that allow it
no ambient, dirty, or humid air enters the cabinet. to meet the requirements of the most
ITW Vortec
demanding applications.
Mitsubishi Electric Automation Inc.
www.vortec.com
https://us.mitsubishielectric.com/fa/en
Wireless access point Distributed control system

The FL WLAN 1101 wireless module combines access The EcoStruxure Foxboro distributed control system
point and antenna technologies in a single housing. An (DCS) is IoT-enabled and features an open and interoper-
innovative form factor and an able system architecture and platform. With patented,
IP-rated housing make the FL customizable real-time accounting (RTA) models built in,
WLAN 1101 ideal for out-of- EcoStruxure Foxboro DCS allows users to evaluate the
the-cabinet mounting. With real-time financial performance of an industrial operation
strong, dual internal anten- directly at the equipment asset level. EcoStruxure Fox-
nas, it provides a powerful, boro DCS features high-capacity, high-availability control
cost-effective wireless solution processors; more powerful,
to keep a user’s devices con- fit-for-purpose I/O; intuitive,
nected. The WLAN 1101 is role-based engineering tools;
designed for industrial environments. It is shock-proof, and enterprise-wide analytical
according to IK08, so it can even withstand strong tools and capabilities.
mechanical loads. Schneider Electric
Phoenix Contact www.schneider-electric.com
www.phoenixcontact.com/us
Central processing unit Distributed safety controller

The Simatic S7-1500 technology central processing unit The Simatic S7-1200 distributed safety controller with
(CPU) combines an expanded range of motion control Profinet can handle standard and safety-related automa-
functions in one controller. The benefits of this technology tion tasks—such as protective
CPU include standard, safety, and motion control func- door monitoring in a single
tions on one CPU; device. It supports Profisafe,
extended motion allowing safety-related devices
control tasks such to be connected via Profinet.
as gearing or cam- Therefore, the safety functions
ming seamlessly built into Sinamics drives can
integrated in the be used directly via Profinet.
TIA Portal; and a The controller also reduces the
high degree of amount of wiring needed, saves
engineering efficiency due to graphic and tabular configu- space, and supports more flexible safety concepts.
ration and optimization of cams in the TIA Portal. Siemens
Siemens www.usa.siemens.com
www.usa.siemens.com

2017 Product of the Year
Intelligent IIoT gateway Current, voltage
The Simatic IOT2040 is an open platform gateway measuring module
designed for acquisition, The Simocode Pro current/voltage
processing data directly measuring module contributes to the
in the production envi- provision of motor data. The current/
ronment transferring it voltage measuring module enables
from and to the cloud or users to achieve a high degree of
company IT level. The measuring accuracy and a wide mea-
Simatic IOT2040 can be suring range simultaneously. This enables Simocode Pro
integrated into an exist- to also be a sensor for motor data. With this measuring
ing plant. It is therefore an economic and safe alternative module, users get improved measuring accuracy for all
to completely retrofitting older machines. Retrofitting can measured values. This allows users to not only measure
also take place gradually for individual machines. Simatic motor current but also voltages up to 690 V and monitor
quality ensures reliable long-term operation in the rough power-related measured quantities.
industrial environment. Siemens
Siemens
www.usa.siemens.com
www.usa.siemens.com
SCADA software Block PLC

VTScada 11.3 SCADA software is designed for plant, The TBEN-PLC is a compact, IP67 PLC with CODESYS
telemetry, or hosted systems of any size. The unique 3 for controlling small or modular machines. The wide
design integrates all core variety of fieldbus communication protocols supported
SCADA components into underlines the flexibility of the TBEN-PLC; when used
one easy-to-use package. It as a master/scanner, the
replaces third-party add-ons device supports the indus-
with integrated features like trial Ethernet protocols
security, reporting, historian, Profinet, EtherNet/IP, and
alarming, alarm notification, Modbus TCP, as well as
version control, and thin clients. VTScada is used in a wide Modbus RTU, CANo-
variety of industries including water and wastewater, oil pen, and SAE J1939. The
and gas, tank farm monitoring, power generation, manu- TBEN-PLC can be used
facturing, agriculture, airports systems, broadcasting, as a remote I/O device for industrial Ethernet networks,
manufacturing, and marine. enabling use as a protocol converter or gateway.
Trihedral Engineering Ltd. Turck Inc.
www.trihedral.com www.turck.us
Compressed Air Rotary screw air compressor

The Next Generation R-Series 200- to 250-kW rotary
Digital flowmeter screw air compressor is designed to improve overall
system efficiency for
The digital flowmeter with wireless capability uses a
applications with high-
Zigbee mesh network protocol to measure and monitor
capacity air requirements.
compressed air usage, trends,
The compressor is avail-
and historical data. The flowmeter
able with single-stage
has a range of 30 m and transmits
air end, or two-stage air
data to an Ethernet-connected
end designed to increase
gateway. Each meter and gateway
airflow by up to 21%. The
is configured for security and has
fixed-speed model is 16%
128-bit encryption for the wireless
more efficient compared to legacy products, while the
transmissions. Measuring compressed air is the first step
variable speed option is up to 35% more efficient com-
toward identifying high compressed air use areas, com-
pared to the industry average.
pressed air leaks and optimizing air use.
Ingersoll Rand
Exair
www.ingersollrand.com
www.exair.com

INNOVATIONS
Compressed Air
Oil-free rotary screw compressor Air compressor
The CSG-2, DSG-2, and FSG-2 series of oil-free rotary The LS Series air compressor uses an air end design
screw compressors cover that combines bearing technology with a larger rotor
flows from 192 to 1,774 profile for increased energy
cfm, pressures from 45 to efficiency. The air end fea-
145 psig, and are avail- tures all internal porting,
able from 50 to 450 hp. meaning fewer compo-
Available air-cooled or nents are needed, which
water-cooled, the two- helps increase durability.
stage oil-free air compres- The LS Series features a
sor has been designed patent-pending package
with energy efficiency, design in which all components are specially designed,
easy maintenance, and low noise levels in mind. The core engineered, and manufactured to perform at the highest
of this versatile model’s top performance is the premium, levels. The LS Series also features a touch screen control-
two-stage compressor air end. ler for intuitive operation.
Kaeser Compressors Inc. Sullair Inc.
www.kaeser.com www.sullair.com
Electric Motors & Drives

Food safe stainless steel motor Common mode choke
The Baldor-Reliance Food Safe stainless-steel motor is The CoolBLUE common mode choke with NaLA differ-
designed with advanced sealing and exceeds IP69K to ential line choke absorbs high
maximize motor life in high pres- frequency damaging current
sure, sanitary cleaning environ- created by variable frequency
ments. The high ingress protec- drives (VFDs), reducing motor
tion-rated enclosures offer fully bearing damage. CoolBLUE
encapsulated windings, sealing cores are designed to signifi-
the motor inside and out. Com- cantly reduces the over volt-
bined with a laser-marked name- age peaks at the motor termi-
plate and a footless mounting design, crevices are kept nals, but also suppresses the
to a minimum and allow the motor to withstand clean-in- asymmetrical EMI currents that
place procedures. A 3-piece rotatable conduit box allows are generated by the parasitic capacities of the motor
easier access to route incoming power supply. itself together with the motor cable.
Baldor Electric Co. MH&W International
www.baldor.com www.coolblue-mhw.com
AC drive with PLC Permanent magnet motor

The Unidrive M300 ac drive includes an onboard program- The UlteMAX motor is a perma-
mable logic controller (PLC) and is designed to provide nent magnet motor offered in
flexible integration with safety models ranging from 3 to 15 hp.
and communications. The The motor has three-phase/460
Unidrive M300 is ideal for V/60 Hz integrated DPT control
applications that require cost- with variable torque loads, and
effective integration into safety is designed to be scalable to
systems. With two safe torque 230 V, three-phase/60 Hz appli-
off (STO) inputs, an onboard cations. The UlteMAX is 5.5-in. wide and weighs less than
PLC, and an SI interface for a fieldbus, industrial Ethernet half the weight of a conventional radial motor. The motor
or extended I/O options, this feature set ensures Unidrive is designed to be used with plenum fans with speed
M300’s flexible integration with any system. ranges from 500 to 5,200 rpm.
Nidec Control Techniques Regal Beloit America Inc.
www.controltechniques.com www.regalbeloit.com

IIoT smart gear drive Servo motor
The V-Class IIoT smart gear drive is a digitally-connected The Allen-Bradley Kinetix VPC servo motor is designed
solution designed to to improve productivity and
monitor oil health in efficiency in continuous-duty
real-time. It also detects applications. A cooling fan
vibration, load, speed, and cooling fins on the motor
and throughput, saving provide increased torque and
hours of manual effort and power output. Encoder options
wait time. The internet- with improved resolution and
connected edge device accuracy provide more precise
has the capacity to trans- and responsive control. The
late product performance data and analytics into alerts servo motor uses robust bearings to improve L10 bear-
and recommended actions—to become a fully predictive ing life by up to 60%. An optional single cable for power
model for optimal asset management, providing the tech- and feedback helps reduce installation, setup, and main-
nology to address a variety of customer pain points. tenance time.
Rexnord Rockwell Automation
www.rexnord.com www.rockwellautomation.com
AC drive Process drive system

The Allen-Bradley PowerFlex 755T drive is designed to The Altivar Process 680 is a process
provide harmonic mitigation, regeneration, and a com- drive system designed for low har-
mon bus solution to reduce monic applications. The active front
energy costs, add flexibility, end drive feature a three-level input
and increase productivity. It switching stage, which reduces com-
features TotalForce technol- mon mode voltage and improves
ogy, which provides motor both performance and efficiency.
control through precise, These benefits are a result of the new
adaptive control of veloc- drive system’s custom filtering and a
ity, torque and position for design unique to the industry. It reach-
electric motors. TotalForce es a total distortion factor of around
technology incorporates several patented features that 2.3% and fulfills the requirements per
are designed to help optimize a user’s system and main- IEEE 519.
tain productivity and optimize the user’s system. Schneider Electric
Rockwell Automation www.schneider-electric.com
www.rockwellautomation.com
Medium-voltage drive Web server module

The Sinamics Perfect Harmony GH180 medium-voltage The Sinamics V20 Smart Access web server module is
drive for low power applications features a PCB-based designed to mount directly onto the drive, transforming
power cell with reduced part count for increased com- a mobile device or laptop into a virtual operator panel
pactivity. The Sinamics Perfect for drive control. By pro-
Harmony GH180 drive is IEEE viding a Wi-Fi hot spot, the
519-compliant and compatible wireless connection on this
with any motor type, including module facilitates setup,
induction, synchronous, perma- programming, commis-
nent magnet, and round rotor sioning, production moni-
motors. The drive also supports toring, and maintenance
480 or 600 V input voltages up to on a variety of machines
400 A—making this drive ideal and production equip-
for new or retrofit applications of ment. An embedded graphical user interface enables
existing motors. easy use of the Sinamics V20 in every phase of operation.
Siemens Siemens
www.siemens.com www.siemens.com

INNOVATIONS
Stiff shaft motor Geareducer
The Simotics AboveNEMA 2-pole stiff shaft 8010 frame The Marley M Series Geareducer is designed to directly
is a motor designed for replace gearboxes found in
petroleum and chemical non-Marley cooling towers.
applications. The 2-pole The footprint of the M Series
stiff shaft 8010 frame motor is designed to eliminate the
features a rotor design and need to replace or add other
construction to allow opera- tower components such as
tion of a motor and a drive the fan hub, driveshaft, or
application up to an industry adaptor plate. Simplified
leading 7,500 hp without replacement means the M
concern related to sub synchronous speeds. By design- Series offers significant sav-
ing out the critical speed, users can safely operate their ings in components and labor costs. The M Series also
application in a wider speed range, creating application eliminates the need for additional pumps, filters, or cool-
flexibility and system efficiency. ers to run properly.
Siemens SPX Cooling
www.siemens.com www.spxcooling.com
Electrical Safety
Discrete output module Double-door safety switch
The SIO8.20 DO is a 20-channel low-voltage discrete out- The double-door line isolation switch features an innova-
put module. The SIO8.20 DO enables software-selectable tive two-door design with an internal barrier that isolates
electronic fusing, latching, and the fuse base from line-side power.
fail-safe shutdown for each 24 V The switch provides lowered exposure,
dc output at 1 A max current per enhanced safety, and improved uptime
channel. It provides galvanically- when accessing the load-side fuse com-
isolated output switching in a rug- partment. The switch enables main-
ged, all-metal enclosure. Delivering tenance personnel to prevent doors
programmable electrical capability from being opened when the switch is
within the cyber secure Bedrock energized: an interlocking mechanism
control platform reduces cost, keeps the door closed when the handle
maintenance, and vulnerability of external electrical con- is in the ON position, while a defeat
nectors. mechanism enables user access when necessary.
Bedrock Automation Eaton Corp.
www.bedrockautomation.com www.eaton.com
Inspection window Arc flash relay

The CAP-ENV-PDS inspection window provides reliable The AF0100 is a compact arc flash protection relay sized
infrared, ultrasound, ultraviolet, and visual inspection. This to fit tight footprints and bud-
window allows the user to perform closed panel airborne gets. Measuring 90 x 128 x 60
ultrasound inspections of electrical mm deep while being DIN-rail
equipment. It detects early warning and surface-mountable, the
signs, including arcing, tracking, AF0100 can be retrofitted eas-
and corona. The CAP-ENV-PDS ily into existing switchgear or
includes a built-in ultrasound pre-installed in equipment with
sensor and 3.5-mm jack that works in conjunction with little or no configuration. The relay detects light from an
handheld ultrasound detectors. These inspections can impending arc flash and rapidly trips to reduce potential
be performed without the need for any special personal damage. Its two light sensor inputs accept point sensors
protection equipment since the equipment is kept closed and fiber-optic sensors for installation flexibility.
at all times. Littelfuse Inc.
IRISS www.littelfuse.com
www.iriss.com
50 November
50 • • November 2014 2017
PLANT PLANT
ENGINEERING
ENGINEERING www.plantengineering.com
www.plantengineering.com
Electrical Safety
Overload relay Square body fuse
The MP8000 Bluetooth-enabled overload relay is The PSR Series square body fuse combines extreme
designed to communicate current limitation, excellent cycling capability, and low
directly with a mobile watt-loss design in a direct
device. The MP8000 bus-bar mount construction
allows maintenance per- with blown fuse indication. The
sonnel to communicate square body design accommo-
with the relay from up to dates high current ratings with
30 ft away using an app enhanced dc performance in a
on an iPhone or Android smaller footprint than the tra-
smartphone or tablet ditional round body style of high-speed fuses. Features
computer. A worker can set up the relay, view real-time include flexibility to mount directly to a system’s bus-bar
data and troubleshoot fault codes while the panel door and an optional micro switch is also available for remote
remains closed to minimize potential shock and arc flash indication requirements.
hazards and help create a greater level of safety. Littelfuse Inc.
Littelfuse Inc. www.littelfuse.com
www.littelfuse.com
Absence of voltage tester Circuit breaker

VeriSafe minimizes risk to electrical hazards by verifying The CBMC circuit breaker comes with an IO-Link inter-
the absence of voltage before equipment is accessed, face for protecting four loads at 24 Vdc in the event of
making it easier for quali- overload and short circuit. Each channel is electronic and
fied electrical workers to adjustable from 1 to 10 A for standard versions, and 1 to
determine an electrically 4 A for NEC Class 2
safe environment in a frac- versions. The circuit
tion of the time compared breaker can also be
to hand-held portable test programmed at the
instruments. VeriSafe tests factory to pre-spec-
the instrument itself, veri- ified current values.
fies installation, checks for This reduces installa-
voltage, verifies installation and retests the tester; all auto- tion and initial set-up
matically performed in sequence with no risk of exposure time.
to electrical hazards at the push of a button. Phoenix Contact
Panduit www.phoenixcontact.com
www.panduit.com
Surge protective device Stainless-steel

The Termitrab surge protective device wall-mount enclosure
is designed for measurement and The stainless-steel, wall-mount enclosure with a 3-point
control applications, and starts from latching system that meets UL
an overall width of 3.5 mm. This means Type 4X protection ratings comes
that the protective device can protect in 24-, 30-, and 36-in. sizes. The
up to 572 signals against surge volt- 3-point latching system delivers
ages on just 1 m of DIN rail. The inte- better resistance to harsh indus-
grated disconnect device is designed trial environments where high
to ensure safe behavior in the event of humidity, saltwater, moisture, and
overload. It signals the status on each other corrosive materials are pres-
individual protective device mechani- ent. The latching system is paired with a foamed-in-place
cally without auxiliary power. gasket and knife-edge flange trough collar to create a
Phoenix Contact
tighter door seal to resist contamination by diverting liq-
www.phoenixcontact.com
uids, dirt, and dust away from the enclosure.
Rittal Corp.
www.rittal.com
www.plantengineering.com November
PLANT ENGINEERING
PLANT ENGINEERING 2017
November 2014 • • 51
51
INNOVATIONS
Electrical Safety
Remote monitor HMI
Modular contactor Sm@rtGear offers remote monitoring, configuration, and
The Sirius 3RT1 certified contactor is designed with an control of intelligent devices
integrated fail-safe con- across low- and medium-voltage
nection, making it possible motor control and power distribu-
to attain SIL CL2 with one tion equipment. By monitoring
contactor or SIL 3 with two and controlling systems remotely
contactors, according to IEC via a human machine interface,
62061. The S6 to S12 (100 to operators avoid the dangerous arc
400 hp at 480 V) contactor boundary near the equipment. The
versions are suitable for direct technology also has the capability
control from failsafe control- to learn from current operations to
lers and feature a certified suggest predictive maintenance
digital input for activation from fail-safe or standard con- actions and features an expedited
trollers. They are also available with non-removable, lateral “search and repair” with system diagnosis that can be used to
auxiliary switches. quickly identify a power distribution’s root cause.
Siemens Siemens
www.siemens.com www.siemens.com
Energy Management
Uninterruptible power system Uninterruptible power supply
The 93PM uninterruptible power system (208/220 V The 9900CX uninterruptible power supply (UPS) provides
model) features deployment and offers 1400, 1750, or 2100 kVA of power in one unit. The modu-
enhanced business continuity and lower lar design affords the
total cost of ownership over critical infra- capability of providing
structure. The 208/220 V model delivers internal redundancy up
improved uptime in the event of a power to 1.75 MVA in a single
loss or outage to a variety of facility types, enclosure. The 9900CX
including multi-tenant and co-location facili- can be paralleled with
ties and edge data centers. The included up to six units for capac-
lithium-ion battery offers exponentially lon- ity or N+1 redundancy
ger battery life and lighter physical weight and delivers high power density per square foot of floor
than standard valve-regulated lead-acid batteries. space. The UPS reduces operating and cooling costs and
Eaton is ideal for large data centers.
www.eaton.com Mitsubishi Electric Power Products Inc.
www.meppi.com
Power management software Environmental Health

EcoStruxure Power Monitoring Expert is a complete
supervisory software package for power management
applications. The software collects and organizes data Trailer temperature control
gathered from a facility’s electrical The AeroTec AC trailer safety device provides safe conditions
network and presents it as mean- inside trailers, which can reach temperatures of up to 130°F.
ingful, actionable information via It works by taking conditioned air and circu-
an intuitive web interface. Power lating in through the entire trailer in a high-
Monitoring Expert enables users to velocity column, reducing temperatures within
improve operational efficiency and seconds. With the AeroTec AC, temperatures
reduce energy-related costs, ensure electrical network reli- can be quickly reduced by up to 30°F. Provid-
ability, and optimize equipment utilization and the cost of ing a safe and comfortable work environment
operations. Version 8.2 includes several security updates, is imperative to employee productivity, and
providing enhanced cybersecurity features. this device makes it easier than ever.
Schneider Electric DL Manufacturing
www.schneider-electric.com www.dlmanufacturing.com

Environmental Health Fluid Handling
Forklift spill kit Filter media
The PIG Forklift Spill Kit contains basic spill response The PurePower filter media features advanced microglass
materials to quickly stop the spread of a spill at the source materials and a unique
and protect the first responder. The spill kit is installed six-layer design that deliv-
with hanging straps that allow it to be mounted onto the ers 50% more dirt holding
seat or rear beam capacity, helping reduce
of a fork truck, hydraulic system total
cherry picker, or other cost of ownership. Patent-
mobile equipment. pending Cyclone effect
The PIG Oil-Only technology guarantees that
Forklift Spill Kit in Bag fluid flows along a tangent
combines an ability before moving down to the
to quickly respond to bottom of the filter in a spiral motion. This ensures any
safety hazards with heavy dirt particles are delivered to the outside so filter
maximum accessibility and convenience. pores are not blocked prematurely.
New Pig Bosch Rexroth
www.newpig.com www.boschrexroth-us.com
Atomizing nozzle Ultrasonic flow system

The ¼ NPT No Drip internal mix 360-degree hollow cir- The Sitrans FS230 clamp-on ultrasonic flow system com-
cular pattern spray nozzle bines the Sitrans FST030
atomizes fluid and sprays away transmitter with dependable
from the nozzle in all direc- Sitrans FSS200 clamp-on sen-
tions. The ‘no drip’ feature sors. The FS230 digital flow
stops liquid flow whenever meter is a process-optimizing
air flow isn’t present, which solution for measuring flow in
conserves expensive liquids virtually any liquid application.
and prevents ruined product The FS230 digitizes signal
finishes due to drips. This noz- very early in the measure-
zle is ideal where a smooth, ment process for a high signal-to-noise ratio, enhanced
even coating is needed on the inside of ductwork and is measurement accuracy, and reduced susceptibility to elec-
designed for environments with a maximum operating tromagnetic noise. As a result, it meets the most stringent
temperature of 800°F. electromechanical compatibility standards worldwide.
Exair Siemens Inc.
www.exair.com www.usa.siemens.com
Lighting
Cloud-based lighting control Connected lighting system
The SiteWorx Tune lighting control system applies mul- LumaWatt Pro is a distributed network of smart LED light-
tiple lighting control strategies—occupancy sensing, task ing fixtures with the ability
tuning, daylight harvesting, progressive dimming, and off- to capture real-time data.
hour setback—to achieve The network is Internet of
up to 90% energy savings. Things (IoT)-equipped and
It harnesses the power of maximizes potential energy
the Industrial Internet of savings through fixture-fixture
Things to react in real-time controllability. This connected
and automatically act on lighting system offers up to a
energy savings opportuni- 70% savings in energy costs
ties. Tune allows for facilities to customize their lighting as well as up to a 20% reduction in time spent looking for
needs, which can be easily managed through the Site- equipment. The dashboard and specialized apps make it
Worx dashboard on both desktop and mobile devices. easy to view when and where cost savings are possible.
Digital Lumens Eaton
www.digitallumens.com www.eaton.com

INNOVATIONS
Lighting Maintenance Software
Linear LED luminaire Web-based CMMS
The Pauluhn Summit light-emitting diode (LED) luminaire MVP Plant V2.0 is a web-based computerized maintenance
is designed for harsh, hazardous, and industrial environ- management system
ments. The LED lumi- (CMMS) that is truly mobile
naire is engineered to and can be accessed from
provide maintenance- any device. MVP Plant has
free performance, while several modules to make
delivering long life and plant management easier;
high-lumen output for manage everything from
applications in hazardous rated areas. It features a rated inventory to employee
life of over 60,000 maintenance-free hours of operation, wages in one place. Infor-
versatile mounting options, and a robust design to with- mation displayed on the
stand high pressure washing. The Pauluhn Summit LED easy-to-navigate dashboard means critical knowledge about
luminaire is a reliable option, even in the worst operating saving time and money is accessed with ease.
conditions. CMMS Data Group
Eaton www.cmmsdatagroup.com
www.eaton.com
LED high bay

The OmegaLight LED high bay is designed to maximize All-in-one CMMS
efficiency with a eMaint CMMS is a management software that has the
programmable capability to solve all maintenance management problems.
LED technology. It offers functionality for managing work orders and work
The OmegaLight requests, preventive maintenance, purchasing and inventory
LED high bay control, planning and scheduling, asset history, cost tracking,
allows for the condition monitoring, document storage, and robust report-
perfect balance ing in one user-friendly
of light output and cost savings. This high bay can easily and affordable solu-
replace anything from a 2-lamp T12 fluorescent fixture to tion. Through use of
a 1,000-Watt high-intensity discharge metal-halide fixture. saved filters, any facility
The LED is IoT-ready and can help reducing operating can view the data that
costs by over 80%. Power is available at the fixture for matters most to them.
accessories such as video cameras. eMaint
Energybank www.emaint.com
https://energybankinc.com
Blue spectrum Streamlined CMMS

suppression high bay Maintenance Connection V8.0 offers an intuitive and easy-to-
The SpectraLoc high bay is designed to eliminate blue use interface that allows
light wavelengths that can degrade ingredients in a variety for the streamlined man-
of food and pharmaceutical production processes. By use agement of maintenance
of the “Stokes Shift” effect, SpectraLoc converts harm- operations. The effective
ful blue light to green and CMMS can help reduce
yellow light. This high bay asset downtime, improve
combines the energy effi- planning and productiv-
ciency of LED lighting with ity, and help organiza-
blue spectrum suppression, tional stakeholders easily
an option previously unavailable to many industries. It is track and improve per-
suitable for use with most wired or wireless lighting control formance results. Version 8.0 includes more than 100 product
systems. features including device native barcode scanning and global
Hubbell Lighting
search.
Maintenance Connection Inc.
www.hubbellindustrial.com
www.maintenanceconnection.com

Maintenance Tools & Equipment
Device communicator
The AMS Trex is a handheld device communicator built Chip trapper
to work in the tightest spaces The patented High-Lift Chip Trapper works by vacuuming
while remaining comfortable liquid, trapping all solids into a reusable filter bag, and
and convenient. It syncs field pumping out the filtered liquid.
data automatically with the user’s It is capable of moving high
database, eliminating the risk of viscosity liquids, and is available
inaccurate or outdated data. The in 30-, 55-, and 110-gal capaci-
AMS Trex is built with Bluetooth, ties. The High-Lift Chip Trapper
USB, and Wi-Fi connectivity, giving features no moving parts, which
the option to use the connectivity means there are no motors that
option that is most convenient. clog or wear out. The drum is
This device communicator allows technicians to identify included and features an auto-
and repair problems while devices are running, all with safety shut off.
one-handed operation. Exair
Emerson Electric Co. www.exair.com
www.emerson.com
Three-phase power monitor Surface condenser

The Fluke 3540 FC is a compact device that monitors
three-phase systems
tube cleaning system
and streams data to the The Surface Condenser Tube Cleaning System makes
cloud. Data measured by cleaning faster and easier. Just add the correct gun,
the monitor is accessible squeeze the trigger, and
on any device with cloud pressurized water propels a
connectivity. Alarm set- scrubber, coil tube brush, or
tings notify users imme- other projectile to remove
diately when measure- even the toughest scale.
ment values are outside The Surface Condenser
specified thresholds. Maintenance technicians can set the Tube Cleaning System is
system up and begin monitoring in a matter of minutes, ruggedly built with a heavy-
with the sensors transmitting measurements to the cloud duty cart. With up to 400 psi, it is the power plant profes-
as frequently as one measurement per second. sional’s system of choice for hard deposits.
Fluke Goodway Technologies
www.fluke.com www.goodway.com
Cordless torque multiplier Lubrication, greasing assistant

The QX Series Cordless Torque Multiplier is a high-torque In order to provide optimal lubrication parameters, the
bolting tool that achieves up to 1,475 ft-lb of torque. It SDT LUBExpert Acoustic Lubrication and Greasing Assis-
is equipped with advanced technology, communication, tant guides lubrication techni-
and control features to ensure cians before, during, and after
reliable and accurate bolting regreasing. It helps technicians
in high-risk environments. This through every step of the lubrica-
QX torque multiplier gener- tion process, from informing them
ates 160x the torque of a stan- of the right lubrication to use to
dard tool. It has multiple user- directing them to the prime loca-
programmable configurations tion. The SDT LUBExpert includes
that can be customized directly on the tool or changed software to help technicians trend
from a computer. It can store up to eight programmed friction levels before and after lubrication and generate
strategies. grease consumption reports for each asset.
Ingersoll Rand Ludeca
www.ingersollrandproducts.com www.ludeca.com

INNOVATIONS
Maintenance Tools & Equipment
Shaft alignment system Industrial computer
Rotalign Touch is a cloud-enabled touchscreen laser shaft The Allen-Bradley VersaView 5400 industrial computer is
alignment system. If offers 3-D display animations, capaci- available with or without an
tive touchscreen, and integrated display. Display
guidance. The voice- versions feature a modern,
control feature allows edgeless glass design with
for hands-free opera- 10-point, capacitive multi-
tion, and it can be oper- touch screen. The computer
ated with Bluetooth is equipped with a quad-
headsets. This system core Intel Atom E3845
comes with software processor and 128 GB solid-
that allows for work orders to be sent from the cloud state drive. This industrial
to a mobile device, and for measurement results to be computer also helps reduce maintenance needs. It uses a
sent back for advanced reporting. Rotalign Touch is fully supercapacitor, which mitigates the need to replace batteries
designed to meet the requirements of the smart factory. and simplifies air shipment logistics.
Prüftechnik Rockwell Automation
www.pruftechnik.com www.rockwellautomation.com
Multipoint measuring system

The Sitrans TO500 measuring system can be used for Stainless fitting
evaluating a The MegaPress Stainless fitting makes secure connections in
large number 7 seconds or less. It can help reduce installation time by up to
of temperature 60% when compared to welding
measuring sen- or threading, thus reducing the
sors. It can be need for downtime for repairs. The
connected to fitting works with existing Mega-
up to 48 sen- Press jaws and ring sets. Detecting
sors on the transmitter at four channels. With a capacity unpressed fittings is made easy
of four measuring probes, the Sitrans TO500 can process with the Smart Connect feature.
192 points simultaneously. The system is also particularly The fitting is flame-free, provid-
suited for operation in tight spaces. It allows for the quick ing a safer work environment for
detection of overheating, preventing damage to the pro- technicians.
cess, plant, and environment. Viega
Siemens www.viega.com
www.siemens.com
Material Handling Systems

Dynamic dock seal Air-operated conveyor
The Dynamic Dock Seal elimi- The 316SS Threaded Line Vac converts ordinary pipe into
nates the struggle of sealing conveying systems. It is designed to attach to plumbing pipe
trailers with complex variables. couplers, sanitary flanges, and
Instead of trying to reach the other pipe fittings, making it
trailer to the seal, the Dynamic simple to build a complete
Dock Seal brings the seal to system. The sizes of this
the trailer. Actuators are used stainless steel air-operated
to lower the head pad down conveyor simplifies sampling
to meet the top of the trailer gas streams, sampling grains
sealing out water and light. The or other ingredients, moving
Dynamic Dock Seal fits any trailer from 12 to 13.5 ft and small parts, or transporting
can be automated to any system. scrap or product out of small spaces.
DL Manufacturing Exair
www.dlmanufacturing.com www.exair.com

Material Handling Systems
Industrial door activator Mounted ball bearing
SentryPost V2 is wired into the door controller and will The SealMaster large bore performance gold line mounted
detect forklifts, pallet jacks, people, and other objects. ball bearing features an
The door will remain open until axial groove design to save
obstructions clear. The field of acti- time and reduce damage.
vation can be adjusted to suit any The groove makes it easier
space. SentryPost can be used for to remove and replace the
warehouse traffic safety, used at bearing by providing clear-
a loading dock and warn person- ance from the burr created
nel of movement, or be used as a by the setscrew used to lock
hold open device. The SentryPost the bearing to the shaft. It
was designed to require minimum also allows for the reuse of
maintenance and ease of adjust- shafting with minimal cleanup. There is no impact on bearing
ment. performance, load and speed rating, nor ball path roundness.
JAMAS Enterprises Regal Beloit America
www.jamasenterprises.com www.regalpts.com
Concentric locking collar Right-angle transfer module

The design of the SealMaster Skwezloc concentric lock- The System Plast MODSORT right-angle transfer module can
ing collar reduces fretting uniquely transfer and divert even the smallest packages. It
corrosion while maintain- works best with polybags and
ing near perfect ball path small packages, but can eas-
roundness. A circumfer- ily handle bigger boxes. The
ential groove on the inner module can be placed end-
ring bore improves shaft to-end or integrated with con-
grip and reduces raceway veyors to create transfer sta-
distortion. The larger cap tions within conveyor systems.
screw allows for improved MODSORT can help achieve
clamping force to the 50% to 60% energy savings when compared to traditional
shaft. With Skwezloc locking collars, there is no axial conveyors. Pneumatics, lifts, or Z-direction position feedback
movement during installation or risk of preloading the devices are not needed, and it can be integrated with existing
bearing. systems.
Regal Beloit America
Regal Beloit America
www.regalpts.com
www.regalpts.com
Spherical roller bearing

The IIoT Smart PT select mounted spherical roller bearing
Rideable material lift
works with the latest technol- The RiderLift rideable material lift increases material handling
ogy to make users’ jobs easier. efficiency. Purchased and installed at a fraction of the cost of
Each bearing has a unique an elevator, it allows workers
QR code that can be scanned to travel between levels with
to quickly access product their materials, saving time.
information and tutorials. The In addition to increased time
Bearing Mobile Pro mobile efficiency, it improves safety,
app works seamlessly with the reduces fatigue, and mini-
bearings to ensure ultimate mizes lost-time accidents.
accessibility and convenience. Capacity of the lift is 2,500
The bearing is made with cast iron housing that allows for lb, including the rider, and
increased strength. It features a 90-degree mounting col- lifting speed is 20 fpm. It is
lar for holding strength. available in either C or Z loading patterns.
Rexnord Wildeck
www.rexnord.com www.wildeck.com

INNOVATIONS
Material Handling Systems Productivity & Training
Customizable lift truck Asset performance application
The GP040-060 MX Series lift truck is a customizable solu- The Augmented Reality (AR) mobile application combines the
tion that provides operator comfort, dependability, simple digital and real world on one screen,
service, and low total cost making it easier than ever to experi-
of operation. Operators can ence the benefits of AR. Engineers
adjust engine performance can pull out their phones, open the
based on real-time demands. app, and get a live, step-by-step
Selectable modes make it instruction on fixing or working on
easy to boost productivity equipment. AR presents complete
when needed, or maximize systems, procedures, and structures
fuel economy during lighter in a way that pops concepts right off
duty cycles, all while using 14.4% less fuel over 2,000 hours the page. The application is interac-
of operation. Equipped with a PSI engine, the MX trucks tive, convenient, and replaces tradi-
are available in LPG or dual fuel configurations. tional training instructional sheets and videos.
Yale Materials Handling Corp. Eruditio LLC
www.yale.com http://eruditiollc.com
Plant Analytics & Design Training program

The inspired Blended Learning 2.0 (iBL 2.0) training curriculum
Batch software is a highly customizable and reactive program that works to
FactoryTalk Batch V13 improves upon already innovative fit the dynamic needs of
batch software solu- engineers and coaches.
tions. It enhances scal- iBL 2.0 combines seasoned
ability and responsive coaches, in-depth video,
control of distributed, and innovative augmented
skid-level phases with reality teaching methods.
the integrity of plant- iBL 2.0 is driven by direct
level coordination. application of the concepts
With this software, batch sequencing can occur at either to an individual site’s chal-
the controller or the server level. It minimizes the rework lenges through project
required when manufacturers expand from small to larger, based learning. Return on investment for this program aver-
server-based batch systems. Users can access FactoryTalk ages about 30x training cost in the first year of learning proj-
from their mobile devices, from anywhere in a plant. ect implementation.
Rockwell Automation Eruditio LLC
www.rockwellautomation.com www.viega.com
Integrated development Online design portal

environment software The Proficient Program provides access to resources to help
Studio 5000 integrated development environment soft- building professionals design and build smart, high perfor-
ware allows engineers to streamline design and configura- mance facilities that use the
tion processes. The software collaboratively exchanges latest building technolo-
data with popular engineering gies. The program provides
tools, reducing or even eliminat- critical tools, education, and
ing the need for manual data peer-to-peer collaboration
entry. With Studio 5000, engi- needed to navigate market
neers can use pre-developed changes, identify best prac-
applications instead of creating tices, and speed the delivery
custom code, reducing costs of innovative solutions. The
and potential errors. The newest version of Studio 5000 online Proficient portal is designed to learn from member
also improves security by adding license-based content activity and provides customized content based on individu-
protection. als’ areas of interest.
Schneider Electric
Rockwell Automation
www.schneider-electric.us
www.rockwellautomation.com

Safety
Floor-marking stencil Floor mat
The PaintStripe floor marking stencil is designed to offer The PIG Grippy carpeted entrance and floor mat is designed
precise control and measurement when using paint to to keep lobbies, entrances, wait-
mark industrial floors. ing rooms, and walkways safe.
PaintStripe is a paint- The mat’s proprietary adhesive
compatible alternative backing sticks to the floor with
for use in areas where a tight grip and is designed to
abrasive traffic, wet floors, eliminate trip hazards commonly
wash-down conditions or associated with standard rubber-
aesthetics make paint pref- backed floor mats. An engineered
erable over line-marking fiber matrix absorbs a wide variety
tape. Available in continuous or dashed line formats with of liquids and the leak-proof back-
line widths of 2-, 3-, or 4-in., the stencil face features a ing prevents any liquid pass-thru,
repeating 12-in. ruler for accurate measurement and print- protecting floors and providing
ed cut-lines for rapid alignment of 90-degree corners. safer walking surfaces.
Brady Corp. New Pig
www.brady.com www.newpig.com
Restroom floor mat Light curtain system

The PIG Grippy restroom mat is designed to keep rest- The Allen-Bradley GuardShield 450L safety light curtain sys-
room floors cleaner and tem is designed to enhance safety
safer. A proprietary adhe- while improving productivity through
sive applied across the transceiver technology. Five-pin
entire backing ensures plug-ins are available for basic on/off
the mat stays in place with functionality, while eight-pin plug-ins
no shifting, curling or flip- provide manual and automatic restart
ping up; minimizing slip with external device monitoring.
and trip hazards as well as Advanced function settings are con-
time spent repositioning mats that have shifted. The mat figured through dual in-line package
peels up easily for quick change-outs and disposal. The switches located on the plug-in mod-
restroom mat is permanently infused with antimicrobial ule. The light curtain system is also
technology to prevent the growth of odor-causing bacte- equipped with an active protective field that senses the entire
ria and mold. length of the transceiver.
New Pig Rockwell Automation
www.newpig.com www.rockwellautomation.com
Nitrile glove Gas detector

The Powerform S8+ is a single-use The Vanguard toxic and combus-
nitrile glove technology designed tible gas detector features an open
for use in such applications as manu- WirelessHART 7.2 communica-
facturing, food processing, and tion protocol and can be used to
chemical engineering. The glove detect the presence of methane
is designed to provide improved or hydrogen sulfide. This detector
safety and chemical protection due was developed in collaboration with
to its longer cuff and an irritant-free Chevron to meet the market need
manufacturing process for longer for a cost-effective way to add mul-
wear times. The Powerform S8+ is tiple gas measurement points. The
designed with two layers of advanced polymer, boosting Vanguard detector can be easily
glove durability to ANSI Level 2 puncture resistance, and mounted anywhere and painlessly
making potential glove damage and breaches immedi- incorporated into any WirelessHART
ately visually detectable. networks. The gas detector boasts a 5-year battery life.
SW Safety Solutions Inc. United Electric Controls
www.swsafety.com www.ueonline.com

INNOVATIONS
COMPANY CATEGORY PAGE COMPANY CATEGORY PAGE
AutomationDirect Automation & Controls 42 Exair Compressed Air 53
Baldor Electric Co. Electric Motors & Drives 48 Exair Maintenance Tools & Equipment 55
Bedrock Automation Electrical Safety 50 Exair Fluid Handling 56
Bosch Rexroth Automation & Controls 42 EZAutomation Automation & Controls 44
Bosch Rexroth Fluid Handling 53 EZAutomation Automation & Controls 44
Brady Corp. Safety 59 EZAutomation Automation & Controls 44
CMMS Data Group Maintenance Software 54 FasTest Inc. Automation & Controls 44
Digital Lumens Lighting 53 Fluke Corp. Maintenance Tools & Equipment 55
DL Manufacturing Environmental Health 52 Goodway Technologies Maintenance Tools & Equipment 55
DL Manufacturing Material Handling Systems 56 GTI Predictive Technology Inc. Asset Management 41
Eaton Energy Management 50 Hubbell Lighting Lighting 54
Eaton Electrical Safety 52 Infor Asset Management 41
Eaton Lighting 53 Infor Asset Management 41
Eaton Lighting 54 Ingersoll Rand Maintenance Tools & Equipment 47
eMaint Maintenance Software 54 Ingersoll Rand Compressed Air 55
Emerson Automation Solutions Asset Management 41 IRISS Electrical Safety 50
Emerson Electric Co. Asset Management 41 ITW Vortec Automation & Controls 46
Emerson Electric Co. Maintenance Tools & Equipment 41 JAMAS Enterprises LLC Material Handling Systems 57
Emerson Electric Co. Automation & Controls 42 Kaeser Compressors Inc. Compressed Air 48
Emerson Electric Co. Asset Management 55 Littelfuse Inc. Electrical Safety 50
Endress+Hauser Automation & Controls 44 Littelfuse Inc. Electrical Safety 51
energybank Lighting 54 Littelfuse Inc. Electrical Safety 51
Eruditio LLC Productivity & Training 58 Ludeca Inc. Maintenance Tools & Equipment 55
Eruditio LLC Productivity & Training 58 Maintenance Connection Inc. Maintenance Software 54
Exair Automation & Controls 44 MH&W International Electric Motors & Drives 48
Exair Material Handling Systems 47 Mitsubishi Electric Automation Inc. Automation & Controls 46
Handle the Heat

Inside the Trailer
TEMPERATURES INSIDE A TRAILER
Cool, safe, productive.

Finally a solution.
WITHOUT AEROTEC AC
For dock workers faced with dangerously hot work environments
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2017 Product of the Year Index
COMPANY CATEGORY PAGE COMPANY CATEGORY PAGE
Mitsubishi Electric Power Products Inc. Energy Management 52 Schneider Electric Electric Motors & Drives 46
New Pig Environmental Health 42 Schneider Electric Automation & Controls 49
New Pig Safety 53 Schneider Electric Energy Management 52
New Pig Safety 59 Schneider Electric Productivity & Training 58
New Pig Asset Management 59 Siemens Automation & Controls 46
Nidec Control Techniques Electric Motors & Drives 48 Siemens Automation & Controls 46
Panduit Electrical Safety 51 Siemens Automation & Controls 47
Phoenix Contact Electrical Safety 46 Siemens Automation & Controls 47
Phoenix Contact Automation & Controls 51 Siemens Electric Motors & Drives 49
Phoenix Contact Electrical Safety 51 Siemens Electric Motors & Drives 49
Prüftechnik Maintenance Tools & Equipment 56 Siemens Electrical Safety 52
Regal Beloit America Inc. Material Handling Systems 48 Siemens Energy Management Electrical Safety 52
Regal Beloit America Inc. Material Handling Systems 57 Siemens Inc. Fluid Handling 53
Regal Beloit America Inc. Material Handling Systems 57 Siemens Industry Inc. Maintenance Tools & Equipment 50
Regal Beloit America Inc. Electric Motors & Drives 57 Siemens Industry Inc. Electric Motors & Drives 56
Rexnord Material Handling Systems 49 SPX Cooling Electric Motors & Drives 50
Rexnord Electric Motors & Drives 57 Sullair LLC Compressed Air 48
Rittal Corp. Electrical Safety 51 SW Safety Solutions Inc. Safety 59
Rockwell Automation Electric Motors & Drives 42 Trihedral Engineering Ltd. Automation & Controls 47
Rockwell Automation Safety 42 Turck Inc. Automation & Controls 47
Rockwell Automation Electric Motors & Drives 49 United Electric Controls Safety 59
Rockwell Automation Maintenance Tools & Equipment 49 Viega LLC Maintenance Tools & Equipment 56
Rockwell Automation Asset Management 56 Wildeck Material Handling Systems 57
Rockwell Automation Plant Analytics & Design 58 Yale Materials Handling Corp. Material Handling Systems 58
Rockwell Automation Asset Management 58
Rockwell Automation Plant Analytics & Design 59

To vote: go to www.plantengineering.com/NP4E
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NOVEMBER 2017
Inside:
Connect the physical with
the digital p3
Best practices for industrial
Cloud computing p6
Core technologies make
edge-intelligence possible p10
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PRODUCTIVITY & BEST PRACTICES: EDITOR’S COLUMN
Kevin Parker
Senior Contributing Editor
Workforce education becomes

an essential task
Five essential competencies for the digital era identified
A
t its recent user conference, the always thought- piece. “The readiness and capacity for change is limited,”
ful management of Emerson Automation Solutions said Train.
discussed work’s changing nature. Emerson is expanding its service offerings to help
The U.S. manufacturing sector experienced 4.0% pro- fill the gap. What industry needs, Emerson said, is an
ductivity growth from 1990 to 2000, and 4.7% from 2000 increased focus on education and upskilling along with
to 2007. Analyses of productivity growth statistics can be improved organizational workflows to effectively leverage
highly speculative. At the time, however, experts and media their technology investments. An analysis commissioned
credited computerization for these productivity gains. by Emerson of the organization behaviors of Top Quartile
Since then, productivity growth has stagnated at about industry performers indicated five essential competencies
1.5%. Yet computerization has continued apace. If digita- for the digital era.
lization was the cause of productivity growth in the 1990s Automated workflow allow focus on exceptions requir-
and in the first decade of the 21st century, what caused ing human intervention. Analytics and embedded exper-
the subsequent productivity growth slowdown? tise reduce complexity. Workforce upskilling empowers
Computers today are communication devices in support personnel to acquire knowledge and experience more
of the coordination of work, as much as they are any- quickly. Mobility provides access to information regardless
thing else. If the network is the computer, then advances of location. Change management accelerates institution-
depend on integration, and just 50 years into the com- alization of operational best practices.
puter revolution we’re faced with a multi-layered installed
base. In fact, integration seems to be the constraining Expectations expanding
challenge. Moving forward, while remaining cognizant of “Process control has been digitalized already,” said Pe-
legacy systems, has proved complex and daunting. ter Zornio, chief technology officer, Emerson Automation
Solutions. “Users expect real-time information, embed-
Essential competencies ded expertise, and a closed-loop system. We can now
Another kind of “installed base” is the industrial work do the same thing for other type operations, including
force involved. In the last 40 years, many kinds of work reliability, safety, and energy, for example. In the new era,
were transformed, and quantified, as computerization core production workers will be focused on collaboration,
supported work-process reengineering. interpretation, and analytics, rather than data collection
At the conference, Emerson tackled the topic during a and reporting.”
briefing on “essential competencies for an empowered Where are we at this moment? One last quotation
digital workforce.” taken from the user conference provides a hint:
“The past 30 years have brought fantastic advances “Wireless is arguably the most impactful technology for
in the manufacturing sector, including greater operating industrial manufacturers since the introduction of digital
efficiencies enabled by automation. But the incremental instrumentation more than three decades ago,” said Bob
gains are diminishing,” Mike Train, executive president, Karschnia, vice president and general manager, wireless,
Emerson Automation Solutions, said. Emerson Automation Solutions. “Industrial wireless com-
The silver lining will come with an emerging generation bined with smart sensors are the foundation to support
of technologies able to revitalize productivity gain, as in cloud-based applications, remote monitoring, and other
the former era. However, the work force is the essential IIoT programs over the next decade.” IIoT
www.controleng.com/IIoT IIoT For Engineers NOVEMBER 2017 | 1
IIoT IN THE NEWS
IIoT platforms released

and updated
Suppliers package IIoT capabilities as a solution
K epware released the

KEPServerEX version 6.3
industrial connectivity plat-
Time sync functionality for driv-
ers with EFM capabilities: Users
can now set a custom time sync
According to Schneider, the plat-
form is a “proven solution capability
for engineering, planning and opera-
form. Key enhancements include threshold for any driver with EFM tions, asset performance, and control
improved create, read, update, and capabilities and ensure no synchro- and information management.” With
delete (CRUD) functionality for the nization occurs unless a specific more than 2 million software licenses
configuration API, time sync func- deviation limit is exceeded. OnPoll, deployed at 100,000+ sites world-
tionality for drivers with electronic the new time sync method includ- wide, processing 10+ trillion daily
flow measurement (EFM) capabili- ed in version 6.3, also lets users transactions spanning 20+ billion
ties, a Keyence KV Ethernet driver, configure time synchronization to operating parameters, the platform
and remote project loading via the occur only after an EFM poll. This operates at a scale to support com-
ThingWorx IoT Platform. reduces network traffic and pro- plex and mission-critical industrial
“This release will give users more vides users more control over time operations.
control over their projects, even synchronization. The platform is hardware and sys-
when connecting remotely. With Remote project loading: Taking tems agnostic and can be deployed in
version 6.3 we’ve also added a advantage of the existing security a scaled, modular fashion.
new driver to our industry-leading of the ThingWorx native client The platform includes a wide range
portfolio.” said Jeff Bates, Kepware interface in KEPServerEX, users can of commercial options (Subscription,
product manager. now import a KEPServerEX project SaaS, Perpetual) and deployment
Along with the Keyence KV Ether- from a local file store and push the flexibility (on-premise, cloud-based)
net driver, KEPServerEX version 6.3 project down to any connected for all its available functionality. This
also includes: instance of KEPServerEX. lowers total cost of ownership with-
Enhanced CRUD functionality for Users can easily adjust network out compromising risk, data security,
the configuration API: Configuration settings and deploy KEPServerEX and performance requirements.
API users can now remotely trigger projects remotely—while manag- The domain-specific functionality
project saves for any instance of ing all of their machine instances of the industrial software platform
KEPServerEX, create an object with from a single ThingWorx platform enables business excellence: sup-
a child hierarchy in a single transac- interface. ports engineering, operations, asset
tion, and create multiple objects in management and people enable-
a single transaction. Configuration Industrial software ment. The information management,
API users can also now make bulk platform reintroduced business process knowledge and
changes to the configuration and Schneider Electric announced decision support capability available
trigger ATG, enabling faster changes EcoStruxure Industrial Software across the modules of the platform
on larger projects. KEPServerEX Platform, an integrated, modular are specific to industry problems.
version 6.3 enables users to interact software suite that delivers func- They allow companies to upgrade
less with the local configuration tionality to address operational and competencies, document operational
and easily write common code for business imperatives in industrial experience, and develop the next
objects in disparate projects. and infrastructure markets. generation workforce. IIoT
2 | NOVEMBER 2017 IIoT For Engineers www.controleng.com/IIoT

WORKPLACE TRANSFORMATION
Connect the physical

with the digital
Leaders say, don’t let culture impede technology progress
By Dr. Keshab Panda techniques support these efforts. IIoT IIoT are to enable augmented opera-
gives these companies an opportunity tions, human-robot collaboration, ad-
B
ridging the divide between to go beyond Six Sigma, fool-proofing vanced digital-product development,
the physical and the digital many activities and processes related data-driven control of operations, and
worlds, the Industrial Internet to operational efficiency. predictive maintenance.
of Things (IIoT) transforms how com- These trends see support in a survey Early adopter feedback shows that
panies function and how work gets from L&T Technology Services and the transition to an IIoT ecosystem
done, based on gains in sensor and ARC Advisory Group conducted at depends on employee initiative. The
microcontroller technology, connec- this year’s ARC Forum. Half the survey survey also highlights that 42% of
tivity, and analytics. These emerging respondents were with large corpora- business leaders feel that organiza-
technologies are also conceptualized tions having more than $10 billion tional culture acts as an impendent
as Industrie 4.0. in revenue. According to the survey to IIoT adoption. Capital expenditure
Businesses focus on operational results, 57% of business leaders and concerns are also prevalent.
excellence to streamline and tighten organizations embrace IIoT for opera- While about 40% of organizations
production processes. Six Sigma tions-related work. Key focus areas for said their companies are at the pilot
The positive impact of IIoT can be short-term operational efficiency, but it also can have a
long-term influence on resource optimization, product design, and automation. All graphics courtesy L&T Technology Services

WORKPLACE TRANSFORMATION
While conventional IIoT frameworks

are available, a scalable and long-
term approach integrates IT, OT, and
BT. While IT deals with increasingly
large databases, OT is about physical
devices and processes, and BT is about
business software applications.
Two typical characteristics of any
IIoT-based system include informa-
tion processing on a 24x7 basis and
real-time constraints imposed by the
environment.
A comprehensive IIoT architecture
might include sensors, for detecting
An IIoT-enabled framework streamlines and integrates a value chain, including with appli- events or changes; edge gateways that
cations in predictive maintenance, plant performance optimization, and asset tracking. aggregate and filter sensor data; IIoT
Cloud-enabled platforms, including
smart-signal aggregators and model-
ling algorithms; Big Data analytics,
including machine learning, artificial
intelligence, augmented reality, data
store, and security. The entire system is
meant to run as a managed service.
In addition, technology firms add
IIoT value by offering managed
engineering services as a key building
block of the IIoT system. Managed
services comprise round-the-clock
remote monitoring, predictive main-
tenance using data analytics, and
value engineering. Thus, a new kind
of build-operate-manage model will
An IIoT system includes sensors/chips, edge gateway, IoT platform, cloud services, and increasingly become the paradigm for
data analytics. Bringing together these disparate elements enables the system to be run technology providers.
as a managed service.
Case study examples
stage of evaluating IIoT, 31% said as materials, machines, and plant Business-process management
they’re already in discussions with control systems, interconnect with and enterprise-resources planning
partners and ready for gains on first- information systems and technology integrate systems and processes to a
mover advantage. Predictive analytics (IT). Also connected are users, along degree. The comprehensive structure
and Integrated IIoT are key those with the enterprise business processes enabled by IIoT takes further steps. An
adopting IIoT. and technology (BT). Once connectiv- IIoT-enabled framework can integrate
ity and system data flow between OT- processes starting from the product-
Given the need IT and BT is accomplished, data can be development stage through manufac-
Let’s take a step back to discuss aggregated and analytics applied. turing to supply chains. Possible capa-
what really makes up an IIoT architec- As insights are gained, smart decision- bilities include data-driven inventory,
ture. In IIoT systems, industrial assets making leads to intelligent industrial- remote asset testing and inspection,
and operations technology (OT) such operation and business models. data-driven quality control, remote

service, additive parts manufacturing, IIoT platforms will be a critical suc-
augmented operations, human-robot cess factor for goods makers and ser- Dr. Keshab Panda is CEO and
collaboration, and advanced digital- vices providers. Industries that leverage managing director, L&T Technology
product development. IIoT to integrate data, machines, and Services.
While IIoT is in the early stages people will see impacts on productivity,
of adoption, inspirational narra- efficiency, and operations. IIoT
tives abound. For instance, a global
construction company faced critical
business challenges managing field
assets and equipment. This was ad-
dressed using IIoT technologies that
in turn enabled development of a
remote asset performance manage-
ment framework. The framework
covers 30,000 assets across 500 asset
types. It delivered an estimated 12%
improvement in asset utilization. On-
time asset availability will likely lower
overall costs as well.
Services supporting the solution
implementation included sensor
identification, gateway selection,
sensor-gateway commissioning, and
on-boarding. Such an IIoT system gen-
erates six gigabytes of data per day,
deriving data intelligence from about
2,500 nodes.
In another instance, a consumer-
goods manufacturer addressed the
operational disruptions caused by
frequent compressor failures in its
manufacturing plants using IIoT tech-
nologies. The system used predictive
analytics to proactively estimate time
to failure, using anomaly indica-
tors including temperature, current,
vibration, and other parameters. The
model works at more than 70% inac-
curacy and is estimated to result in
annual savings of about $500,000.
The impact to come

According to a report by McKinsey
& Co. Inc, IIoT will have a potential
economic impact of up to $6.2 trillion
by 2025. McKinsey lists IIoT as one
of the key technologies capable of
economic transformation.
IIoT For Engineers NOVEMBER 2017 | 5
THE DIGITAL WORKPLACE
Best practices for industrial

Cloud computing delineated
Match organizational preferences with the relevant technology requirements
by Melissa Topp However, without the ability to data to a selected cloud service. For
connect devices from behind fire- instance, a manufacturer may have
I
ntegrating the Industrial walls and to publish data securely to updated assembly machines with
Internet of Things (IIoT) into IIoT-integrated applications, organi- units equipped for more advanced
traditional supervisory control zations may miss out on the promise networking. This works well for
and data acquisition (SCADA) and of advanced analytics via Cloud com- companies that can afford such ret-
human-machine interfaces scenarios puting. If your organization is consid- rofitting, but might not be the most
delivers multiple benefits. ering an IIoT integration strategy, the cost-effective means of ensuring IIoT
Increased scalability follows from answers to the following questions connectivity.
secure access to multiple locations highlight some best practices. Legacy industrial machinery can be
via cloud platforms, including the connected to an IIoT infrastructure.
popular Microsoft Azure. Hardware 1. Does your organization However, some add-on hardware
obsolescence can be alleviated, as the already have existing IoT/cloud- connection options often prove,
“heavy lifting” of processor-intensive ready hardware? comparatively speaking, cost-prohib-
analysis can be off-loaded. Connectiv- Some organizations planned for itive. That’s where the concept of IoT
ity is enhanced, as increasing num- IIoT’s emergence, to ensure machin- gateway devices comes in.
bers of devices communicate via IIoT ery electronics and discrete devices IIoT gateways are lightweight
transport protocols. in production facilities can transfer devices that act as a bridge be-
tween on-premise communications
networks and cloud services, at a
fraction of the cost of an equip-
ment retrofit. These edge devices
provide “southbound” data con-
nectivity to end devices, completely
on-premises. A device also provides
a “northbound” communication
path for connectivity between itself
and the cloud.
IIoT gateways incorporate strict se-
curity requirements. They serve as the
delivery mechanism between the data
generated and stored on-premise and
that shared with the outside world.
Intel, through its IoT Solutions Alliance
One benefit of Internet-based automation is that it allows program, supports original-design
centralization of disparate operations, and for expertise to be manufacturers with advanced security
more easily brought to bear at remote locations. All graphics courtesy: Iconics features such as unique hardware IDs,

secure booting, whitelisting, and dis-
abling of onboard peripherals, such as
USB and com ports. Edge management
is of equal concern when considering
IIoT gateways, as they require remote
management once online and are reg-
istered with a preferred cloud service.
Needed security configuration and
other features are incorporated in
IIoT gateway hardware integrated
with comprehensive IIoT software
solutions.
2. Do you already have a

preferred cloud-services vendor?
Decisions about preferred cloud-
services providers might already have
been made at your organization,
based on on-premise computer,
server, and operating system prefer-
ences, as well as those for network In important industries, communications among on-premise machinery and networks with
communication protocols and other cloud services involve numerous industry protocols, including OPC UA and Modbus.
factors. Many industrial users rely
on Microsoft Azure, while others called “cold storage,” abilities and a number of industry protocols,
use Amazon Web Services (AWS) or costs? including:
Google Cloud Platform. These are Where are the data centers locat- OPC Classic specifications are
not the only cloud service options, ed? Will there be anticipated latency based on Microsoft Windows tech-
although they are the biggest. Many due to distance? How will that effect nology, using COM/DCOM (Distrib-
others are available, depending on connected user experience? uted Component Object Model) for
location, each with its own strengths Equally important is how well a data exchange between software
and weaknesses. Cloud-services vendor works with components. The specifications
For organizations that have not existing or planned IIoT devices cover real-time data access (DA),
selected a provider, consider the fol- and software solutions. Selecting historical data access (HDA), alarms
lowing: solutions that embrace open stan- and events (A/E), XML data access
What is the pricing structure? Is it dards can help. Ensuring immediate (XML-DA), and data exchange (DX),
easy to understand, with no possible interoperability is an important first complex data, security, and batch.
hidden fees? step in the best practices for indus- OPC Unified Architecture (OPC
What is the comparative comput- trial cloud computing. UA) is an open standard for ex-
ing power? How many processing changing information in a rich,
nodes are available at any given time? 3. Does your organization prefer object-oriented, and secure way. It
What type of database integration specific communication proto- provides a platform-independent
is offered—SQL or otherwise? What cols, both for internal use and means for mapping and exchanging
types of network integration are pub/sub-based? real-time information while remain-
included—load balancing, DNS, VPN, In important industries, south- ing compatible with the OPC Classic
or another type? bound communications between specification.
What are the provided storage on-premise machinery and net- Modbus is an open commu-
limits? What are the archiving, so- works with cloud services involve nication protocol widely used by
THE DIGITAL WORKPLACE
many manufacturers throughout many open-source examples coded connectivity. Additional value can
multiple industries. The protocol can in multiple popular programming be obtained via IIoT connectivity.
cover serial lines (Modbus RTU and languages. MQTT is recommended This includes connected applica-
Modbus ASCII) as well as Ethernet when network bandwidth is a con- tions that are provided through a
(Modbus TCP). cern and should always be used in Cloud-services provider, which take
Simple Network Management tandem with a secure communica- customer data at the edge and use
Protocol (SNMP) allows devices to tion method such as TLS. it for mobile visualization or analysis.
expose useful information to other Hyper Text Transfer Protocol Examples include energy manage-
connected devices. Almost all tradi- Secure (HTTPS) was designed to ment or fault detection and diagno-
tional IT devices can handle SNMP serve requests and responses in a sis, rapid data historian storage and
requests. computing model for Web-page retrieval.
BACnet is the most widely used communication. It can more easily Some IIoT gateway software
open communications standard in traverse firewalls without the need solutions provide seamless integra-
the building automation industry. for specific IT policies that handle tion for these types of applications.
Some organizations might use server request messages and return Off-the-shelf SCADA and other type
a proprietary communications responses in the form of resources interfaces, analytics, and data histo-
method, either in unison with one such as HTML files, content, and rians can connect to a cloud-servic-
of the industry standard protocols or completion status details. es provider, subscribing to an “IIoT
exclusively. Representational State Transfer Hub” from where these applications
Northbound communications (REST)/JSON provides a stateless can ingest the provided data. One
involve additional protocols, with means for IoT-friendly informa- possible use case is energy monitor-
the need for high security levels and tion access. It leverages the HTTP ing, where IIoT gateway software
often using a pub/sub mechanism. transport protocol to deliver data, running on typical IIoT gateway
These protocols include: typically using JSON, which is a flex- hardware can connect to popular
Advanced Message Queuing ible, lightweight format like XML, energy, gas, or water meters for se-
Protocol (AMQP) provides flow- to define its presentation. cure, real-time infrastructure moni-
controlled, message-oriented com- When considering IIoT hard- toring and timely analytics. Another
munication with built-in options for ware devices and accompanying use case is innovative fault detec-
message-delivery guarantees. Au- software solutions, consider both tion and diagnostics, where the IIoT
thentication and encryption is based your organization’s southbound software suite can alert personnel
on popular Internet authentication and northbound communication of actions to prevent equipment
and data-security protocols such as requirements. failures or excessive energy use.
Simple Authentication and Security Cloud-based computing options,
Layer (SASL) and Transport Layer 4. What additional functional- like other emergent technologies,
Security (TLS). AMQP, optimized for ity is needed for the industrial will continue to evolve. A com-
messaging between devices, sup- cloud-based solution? bined IIoT-integrated hardware and
ports read-and-write functionality By this point, it may be known software solution delivers value in
for command and control or indus- what new equipment is needed the forms of equipment monitor-
trial-automation equipment. to connect electronic assets to the ing, predictive maintenance, and
Message Queuing Telemetry cloud, who the preferred cloud- operational efficiency. Cognizance
Transport (MQTT) was created for services provider will be, and what of suggested best practices can lead
SCADA environments and related communication protocols are consid- to more informed decisions for any
networks, using pub/sub to minimize ered most important. organization’s cloud integration
payloads and overhead with appli- Cloud connectivity initially may plans. IIoT
cation-specific, custom JavaScript have been considered to secure the
Object Notation (JSON) or binary benefits of increased scalability with Melissa Topp is senior director of
formats. Widely accepted in IT ensured security, reduced hard- global marketing at ICONICS
departments worldwide, MQTT has ware obsolescence, and expanded (www.iconics.com)

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THE IIoT LEXICON
Core technologies make

edge-intelligence possible
Development environments combine device management,
connectivity, Cloud, and analytics
By Kurt Au Quickly develop robust applica- network resources. Often it is more

tions. efficient to process data near its
A
s the Industrial Internet of Deploy, update, upgrade, and source and send only the valuable
Things (IIoT) evolves it’s im- maintain large numbers of fraction to a Cloud center.
pacted by the same integra- devices and services. Edge computing is a distributed
tion challenges as previous automa- Transform Big Data into valuable information technology (IT) architec-
tion generations. Besides changing business information. ture in which client data is processed
requirements, many different hard- at the periphery of the network, as
ware and software technologies and Thus, an IIoT product or solution close to the originating source as
applications apply. However, today, must meet challenges related to possible. Time-sensitive data in edge
with open standards, these diverse sensors, connectivity, security, Cloud computing may be processed at the
elements can be melded together to point of origin by an intelligent
‘
deliver solutions. device or sent to an intermediary
In IIoT product and application server located in close geographical
Emerging architectures
development, developers’ goals may proximity. Data that is less time-
include: help companies develop sensitive can be sent to the Cloud for
historical analysis, Big Data analytics,
Support heterogeneous sensors
complex IIoT infrastruc- and long-term storage.
and actuators via the Internet. tures in an integrated Companies must have the means
Integrate heterogeneous wired to manage the edge-computing
’
and wireless connectivity proto- ecosystem paradigm, whether the solution
cols, including Modbus, LoRa, be referred to as an infrastructure,
Sigfox, Wi-Fi, Bluetooth, and architecture, platform, or server. What
others. services, storage, device hardware, Advantech calls its edge intelligence
Port original software to differ- device maintenance, edge/Cloud server (EIS) solution enables local IIoT
ent hardware, including MCU, analytics, system integration, appli- networks to allow edge intelligence
x86/ARM CPU, GPU, and others, cation development, and so on. The to maximize energy efficiency, reduce
and operating systems that first challenge many companies face privacy threats, promote ease of
include Microsoft Windows, is migrating to an IoT application implementation and modularization,
Linux Distributions, mbed OS, while balancing design time, time- and minimize latencies.
Android, and others. to-market, and risk. IIoT software platform services are
Connect cloud services that might based on three key components: the
include WISE-PaaS, Microsoft Anatomy of a network IIoT node, edge-Intelligence server,
Azure, IBM Bluemix, and others. IoT data can be large in volume. and Cloud services. The following
Maintain data ownership and Applications typically have real-time describes some technology choices
integrity and understand its impli- requirements. Transmitting massive any supplier or using enterprise must
cations for security and privacy. amounts of raw data puts a load on make in developing its platform.

An IIoT software platform includes IIoT nodes, edge-intelligence server, and cloud services. Graphic images courtesy: Advantech
For edge-device development, real time, as data is generated. A The last component is Cloud
“southbound” sensing-device con- predictive maintenance and quality services, with SSL/TLS communica-
nectivity must handle diverse sensing capability serves as a proof-of-con- tions and Intel Security both on
protocols, such as Modbus, OPC, cept for edge field prediction. the edge device and for Cloud. The
BACnet, and Wireless IP/NonIP. These Using companies extend this data service can provide the Post-
protocols can be handled by plug-in framework to develop analytic or greSQL DB and Mongo NoSQL DB
modules that process sensor data, data predictive-maintenance modules via as standard offerings, and supports
normalization, and communications. the architecture’s open standard, a standard integration interface
The solution then handles the based on the ubiquitous MQTT with a wide range of data pro-
“northbound” Cloud connectivity communications protocol and the cessing and storage products. The
and intelligence facilities using the modularizing Docker container dashboard website serves as the
microservice container paradigm to technology. IoT application user interface, and
modularize the different Cloud con- Other technologies, like RESTful displays information via browser or
nections and enable device manage- API, MQTT, and Node-RED, facilitate mobile device through visualization
ment. Similarly, intelligence facilities drag-and-drop application develop- facilities such as Azure Power BI or
also adopt the microservice container ment. Node-RED and the configura- Tableau.
architecture to support the data tion utility make it easy to imple- At end of day, a platform pro-
ingestion workload, such as data pre- ment custom applications. Moreover, vides a marketplace for sourcing
processing and cleaning. well-documented SDK-with-MQTT diverse IoT software utilities, provid-
Perhaps most valuable of all is the sample code and the RESTful API ing pure Cloud solutions such as
on-demand, real-time analytics service interface allow advanced developers database, dashboard, and machine-
that extracts pre-set data features, in to fulfill high-level requirements. learning tools.

THE IIoT LEXICON
Further explication a RESTful API that the client and Component interactions can be
Now let’s look a little more server are coupled loosely and the dominant factor in user-per-
closely at some of the technologies remain independent of each other, ceived performance and network
previously mentioned. allowing either client or server efficiency.
MQTT is a simple, lightweight to be coded in any language and Scalability to support large num-
publish/subscribe messaging pro- improved upon at will, which leads bers of components and interac-
tocol used for constrained devices to system longevity and ease of tions among components.
and low-bandwidth, high-latency, evolution. The simplicity of a uniform
or unreliable networks. The service The RESTful API specifies what interface.
publishes its capability and data to it can provide and how it can be Modifiability of components
an MQTT broker and subscribes to used, and requires that details such to meet changing needs, even
specific topics for input interfaces. as query parameters, response while the application is running.
A RESTful API defines a set of format, request limitations, public Visibility of communication
functions that developers use use/API keys, methods (GET/POST/ between components by service
to perform requests and receive PUT/DELETE), language support, agent.
responses via HTTP protocols, such callback usage, HTTPS support, and Portability of components by mov-
as GET and POST. Because REST- resource representations should all ing program code with the data.
ful APIs use HTTP as a transport, be self-descriptive. Resistance to failure at the
they can be used by practically any The properties impacted by the system level despite failures of
programming language and are constraints of the RESTful architec- components, connectors, or
easy to test. It’s a requirement of tural style include: data.
Edge computing is a distributed IT architecture in which client data is processed at the network periphery, as close to the originating
source as possible.

A microservice architecture pat- together using the wide range of translates sensor protocols to the
tern allows a designer to split the nodes in the palette. Flows can MQTT protocol, then passes data to
application into sets of smaller, inter- then be deployed to runtime with the MQTT communication bus.
connected services instead of having a single click. The flows created in
a single monolithic application. A Node-RED are stored using JSON, 2. The SDK layer provides soft-
service typically implements distinct and can be imported and exported ware services such as EIS RESTful
features or functionalities, such as for sharing with others. It can be API, HDD Fault Prediction Algorithm
connectivity management, vertical run at the edge of the network Service, and so on. Developers call
application, or other. Each microser- or in the cloud. The node pack- these services through RESTful API or
vice is a mini-application with its age manager ecosystem is used to MQTT. Users add their own services,
own architecture, including business extend the palette of nodes avail- such as Machine Learning Platform,
logic along with various adapters. able, enabling connections to new Data Base engine, and so on.
Containerization is an OS-level devices and services.
virtualization method for deploying Freeboard provides simple, real- 3. A flow-based layer has Node-
and running distributed applications time visualization of key perfor- RED as the data-flow design engine,
without launching an entire virtual mance indicators. This tool opens plus add-ons such as SUSI API,
machine (VM) for each application. up many possibilities for IoT proj- WSN, and HDD prediction nodes.
Instead, multiple isolated subsys- ects because it’s simple, affordable, Users design logic paths via simple
tems, called containers, run on one open source, and ready for exten- drag-and-drop operations in a
control host and access a single sion. Customers can get started graphical environment.
kernel. Containers share the same for free and then when it is time
OS kernel as the host and are usu- to ramp up, they can select a plan 4.The management and presen-
ally more efficient than VMs, either that’s right for them. tation UI interface layer. A Webmin
of which requires a separate OS for system administration and IoT
instance. Architecture alignment connection configuration uses the
A Docker container wraps up a An architecture of the type under Node-RED-UI for presenting IoT/sen-
piece of software in an independent discussion can be classified into five sor data.
subsystem, complete with file sys- category layers. Each is implemented
tem and everything it needs to run: as its own microservice, using an 5.The Cloud layer may be pre-
code, runtime, system tools, system MQTT broker as the communication installed, as for example, with the
libraries, and anything that may be bus. All microservices interface with WISE-Agent connected to WISE-
installed on a server. This guaran- other microservices or clients. At PaaS/RMM Cloud Server.
tees that it always runs the same, runtime, each instance is a Docker
regardless of environment. container. This makes it easy to de- Concluding observations
Containers hold the components ploy distinct experiences for specific A flexible and scalable hardware/
necessary to run the desired ap- users, devices, or special-use cases. software architecture helps compa-
plication, such as files, environment Containerization is an OS-level nies develop complex IoT infrastruc-
variables, and libraries. The host OS virtualization method for deploying ture in an integrated ecosystem that
also constrains the container’s ac- and running distributed applications. serves different vertical markets.
cess to physical resources—such as Such an architecture can be cus-
CPU and memory—so one container 1. The bottom layer of the tomized, combining several software
cannot consume all of a host’s architecture is the sensor network services; it is then installed on differ-
physical resources. connectivity layer. Wired sensors ent hardware depending on require-
Node-RED is available as open support various types, including ments. IIoT
source, and is implemented by the supervisory control and data acquisi-
IBM Emerging Technology organization (SCADA), Modbus, and OPC-
tion. It includes a browser-based UA. The network connectivity layer Kurt Au is a product manager in the
flow editor that easily wires flows collects data, manages sensor hubs, Advantech Embedded IoT Group.
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