Professional Documents
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CONTINUOUS
PROCESS Playbook
The bottom line on core automation issues
for the continuous processing industries
CONTENTS
Sponsored by:
4 Contributors
7 Introduction
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CONTENTS
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CONTRIBUTORS
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Brooke Robertson
John Rezabek
Michael Thibodeaux
Joe Staples
Dennis Brandl
Chris Wells
President
BR&L Consulting
Steven Toteda
Chairman of WINA
(Wireless Industrial Networking Alliance)
Dave Woll
Bob Rochelle
Vice President
ARC Advisory Group Inc.
CONTRIBUTORS
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Cyle Nelson
Chris Bacon
Ariel Prez
Carl Henning
EtherNet/IP
Profinet
Scott Hibbard
Shaun Kneller
Sercos III
Ethernet Powerlink
Chuck Lukasik
Joey Stubbs
CC Link IE
EtherCAT
CONTRIBUTORS
Control System
Integrators Association
(CSIA)
Automation World worked with CSIA to
gain access to the expertise of its system integrator members to bring you
much of the content in this playbook.
To become a member of CSIA, a
control system integration firm must
demonstrate experience and commitment to the field. Members who
earn CSIA Certification have passed
an independent audit of 80 criteria
covering all aspects of business performance, including general management, financial management, project
management, quality management,
supporting systems, human resources
and more. To maintain their certification, CSIA Certified members must be
re-audited every three years.
For more information about CSIA and
its system integrator members, visit
http://www.controlsys.org
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Chetan Chothani
President
Adaptive Resources
Antonio Manalo
Lead Engineer
Avid Solutions
Alex Palmer
Dario Rossi
Team Lead
Aseco Integrated Systems
Chief Engineer
Aseco Integrated Systems
Robert Snow
Russel Treat
President-CEO
Enersys Corp
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INTRODUCTION
By David Greenfield
Automation may not be such a big word when it comes to letter count, but when it comes
to meaning and concept its a doozy. The term automation encompasses everything from
controls, sensors, networks and interfaces to motors, drives, actuators and software. When
youre deeply involved with the production operations typically conducted by facilities
dealing with chemicals, metals, mining, or oil & gas, all the potential automation applications
that must also be considered can boggle the mind.
Knowing how confusing all these technological options can be, Automation World has
developed this continuous processing-focused playbook to provide a resource on some of
the most basic automation issues encountered in the industry.
Using this playbook as a helpful resource, youll have a handy, quick-read reference on topics
ranging from fieldbus and industrial Ethernet basics, operator interface trends, and control
system security to project start-up concerns, system migration issues, and variable speed
drive considerations.
We hope youll find this continuous process playbook to be a useful source of information
now and in the years ahead as you plan for new projects or upgrade existing production
functions.
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contributing writer
Automation World
and
David Greenfield
1. Clearly identify the project specifications. What do you want to do? What is
your existing process? Define operator involvement, quality control issues, interface points
with other systems, and the technological capability available in-house.
2. Conduct a job risk assessment (JRA). Performing a JRA before the start of work
highlights any hazards that could produce undesirable results to personnel or property. A
safety assessment must be completed to ensure that the scheduled work can be performed in
a safe manner and to address any hazards that are uncovered as a part of the review process.
3. Operator training is key. The operators must learn how to navigate and operate
their process in the new control system. The training must be performed just in time (about
two weeks before start-up) so that the information is fresh in their minds. During the
instruction, it is critical that the operators be trained using the operator interface graphics
they will encounter.
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operations departments is critical to the success of the project. Maintenance and Operations
need to schedule their duties with enough lead-time to support the installation and start-up
activities. With enough time, maintenance can even contract back-fill support for the duration
of the project start-up activities. For operations, the work and vacancy relief schedule will
have to be organized so that enough operators are available to cut-over and start-up the
plant. This is especially important if a hot cut-over is involved.
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Over the past decade, the functionality of different control systems has been merging.
Programmable logic controllers (PLCs) now have capabilities once found only in distributed
control systems (DCSs), while a DCS can handle many functions previously thought more
appropriate for PLCs. So whats the difference between the two control approaches, wheres
the dividing line and are there still reasons to choose one over the other?
PLCs grew up as replacements for multiple relays and are used primarily for controlling
discrete manufacturing processes and standalone equipment. If integration with other
equipment is required, the user or his system integrator typically has to do it, connecting
human-machine interfaces (HMIs) and other control devices as needed.
The DCS, on the other hand, was developed to replace PID controllers and is found most often
in batch and continuous production processes, especially those that require advanced control
measures. The vendor handles system integration, and HMIs are integral.
As users demanded more production information, PLCs gained processing power and
networking became common. PLC-based control systems began to function like a miniDCS. At the same time, the DCS hybridized to incorporate PLCs and PCs to control certain
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functions and to provide reporting services. The DCS supervises the entire process, much like
the conductor in an orchestra. Protocols, like OPC, have eased interactions between the two
control systems.
Since PLCs are less expensive and can now perform much like a DCS, wouldnt it make sense
to convert everything to PLCs? The answer, like most things in the world of automation, is that
it depends on the needs of your application. Here are six key factors to consider:
1. Response time
PLCs are fast, no doubt about it. Response times of one-tenth of a second make the PLC an
ideal controller for near real-time actions such as a safety shutdown or firing control. A DCS
takes much longer to process data, so its not the right solution when response times are
critical. In fact, safety systems require a separate controller.
2. Scalability
A PLC can only handle a few thousand I/O points or less. Its just not as scalable as a DCS,
which can handle many thousands of I/O points and more easily accommodate new
equipment, process enhancements and data integration. If you require advanced process
control, and have a large facility or a process thats spread out over a wide geographic area
with thousands of I/O points, a DCS makes more sense.
3. Redundancy
Another problem with PLCs is redundancy. If you need power or fault tolerant I/O, dont try to
force those requirements into a PLC-based control system. Youll just end up raising the costs
to equal or exceed those of a DCS.
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4. Complexity
The complex nature of many continuous production processes, such as oil and gas, water
treatment and chemical processing, continue to require the advanced process control
capabilities of the DCS. Others, such as pulp and paper, are trending toward PLC-based control.
6. Vendor support
DCS vendors typically require users to employ them to provide integration services and
implement process changes.
System integrators perform similar functions for PLC-based systems. It has also become
common for PLC vendors to offer support services through their network of system integrator
partners.
Process control has become increasing complex. Its difficult for any individual to know
everything about these sophisticated systems, increasing the need for vendor support.
Manufacturers also continue to reduce factory staff and a generation of experienced process
control personnel has begun to retire. As a result, the quality of support has become a critical
factor in vendor selection.
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a giant breakthrough
in small readers
Meet the DataMan 50L. The tiny barcode reader that brings
big performance to the food & beverage industry.
Dont let its size fool you. The DataMan 50L is huge in barcode reading performance.
Measuring just 23.5mm x 27mm x 43.5mm and featuring an IP65-rated housing, the
DataMan 50L is premium technology designed for 1-D-oriented barcode reading. The
DataMan 50L delivers read rates that can surpass 99% through Cognexs proprietary
Hotbars image-analysis technology.
The new DataMan 50L is a powerful upgrade for applications that use small laser
barcode scanner systems. Visit us at www.cognex.com/50L.
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PLC Lifecycle
Management
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are asking of their PLC vendors to help them better manage their PLC assets over the long,
continuous operation periods common to the process industries.
1. Life extension. Because of the long periods of time that typically pass between
maintenance shutdowns in process facilities, users need to be able to source and use
components for longer-than-expected lives. Many facilities in the continuous process
industries are still looking at 20 to 30 years as a life cycle for their equipment. Talk to your
vendor about their ability to support backwards compatibility with new components as they
become available over these long lifecycles. These new components should be able to be
integrated into your system without requiring a shutdown for upgrading.
2. Online upgrades. More vendors are coming around to this request of process
industry end users, as it is often the easiest way to upgrade a PLCs logic without shutting it
down or rewiring the I/O. One process industry end user told us: If you look at the total cost
of an upgrade, the cost of the hardware is dwarfed by the cost of labor to re-do things like I/O
rewiring and the cost of the unit shutdown. Therefore, online version upgrades that can be
installed while the PLC is running and that work with the existing I/O is ideal.
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contributing writer
Automation World
and
David Greenfield
Operator interaction with production machinery is critical from both a standard operations
aspect as well as for analytical and safety reasons. Following are some of the most significant
recent developments in operator interface (OI)/human machine interface (HMI) technologies
for the process industries:
Improved graphics provide detailed context for machine data, enable faster analysis, and
facilitate better and more rapid understanding of information. Operators are presented the
right information, in the right format, at the right time. This empowers them to make timely,
informed decisions and to take immediate actions to reduce costs and operational incidents,
improving productivity across the total operation.
Training
The higher level of functionality and interaction embedded in todays HMI better reflects the
essential experience of a machine or process. This is ideal for training, and speeding time-tocompetency among operators. The value provided by HMI in the training arena is reflected
in ease-of-use, higher efficiency and productivity, reduced time to complete tasks, improved
user satisfaction, greater trust in systems, and fewer user errors.
Workforce Demographics
Over the next decade, process industries face the challenge of replacing an aging workforce
with an Internet-driven, computer-savvy, video-gaming generation of employees. Industries
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Operator Interface
Trends
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must preserve, maintain, extend, and institutionalize their workforce knowledge efficiently
and effectively to sustain operational excellence. Improved HMI technology, including HMI
with virtual reality techniques, is helping in this critical effort, providing an effective means
to train the new workforce in ways that dovetail with their generational interests and native
skills.
Virtual Reality
Though virtual reality techniques are primarily being used for new user training applications
related to basic equipment operations, they can also be used to expose personnel to
simulated hazardous situations in a safe, highly visual, and personally interactive way.
Customized simulations of plant layouts, dynamic process operations, and comprehensive
virtual environments can be set up to allow users to move within the virtual plants, make
operational decisions, and investigate processes at a glance. Trainees see the consequences of
correct and incorrect decisions immediately, providing the opportunity to directly learn from
their successes and mistakes.
As you explore available HMI technologies, ask yourself: Is it easy to exchange essential
information from this HMI with different systems or controllers? Is the application code
locked for customization of objects or functions? Will runtime software be able to operate on
different hardware platforms? These are the kinds of questions being discussed between HMI
vendors and their customers, and increasingly the right answers to these questions depends
on the HMIs use of open platform architectures. As HMI products evolve in their use of these
platforms, HMIs will be less proprietary and more open, offering greater freedom to the user
in terms of choice of runtime platforms.
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Think automation is
just another business cost?
Think automation is tactical
and not strategic?
Think no one has enough of the right
resources to execute your automation work?
Among the issues facing HMI developers are userconstrained environments, collaborative work functions,
and facilities for individuals with restricted mobility. These
challenges have led to a number of HMI innovations,
including:
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Looking for a way to implement a flexible production strategy without breaking your budget
or spending weeks or months writing new software code? The answer can be found in ANSI/
ISA-88.00.03-2003, a control industry standard that establishes best practices for automating
batch manufacturing plants and batch control.
Although originally designed for batch manufacturing processes, the ISA-88 standard is also
helping users save time and money in automating continuous production processes.
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The next two levels, process cell and unit, are the building blocks of the production process.
One or more units are contained in each process cell. Each unit is a collection of controlled
equipment.
Within the unit are the equipment and control modules. An equipment module defines a
small group of equipment with a process function and can contain control modules and
subsidiary equipment modules. The control module contains the equipment and systems that
perform the actual process control.
Universal Structure
The standard can be applied to either simple or complex processes, so that one programming
system can be used for all production processes in a plant. Using this methodology, users and
programmers can:
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Broad Applicability
Industry experts say an estimated 50 percent of all U.S. manufacturing is now accomplished
using techniques and technologies consistent with the ISA-88 standard, which has been
proven in thousands of applications and can be applied in either DCS or PLC control
environments.
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The process industries are increasing use of intelligent instruments that provide operators
and plant managers with a broader range of operational information than their analog
predecessors. Now that these instruments have been available for years, its apparent that
the difference in application success with them often hinges on whether or not the company
using them is prepared to take advantage of the benefits they offer.
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Are Intelligent
Instruments The
Right Choice?
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Intelligent instrument capabilities and vendor offerings vary widely. As a result, one of the
biggest challenges to gaining all the benefits offered by intelligent instruments has been the
lack of uniform methods for accessing information. To overcome this, the control industry has
begun setting standards such as Field Device Tool, or FDT, making it easier to communicate
with and configure different devices from multiple vendors.
Core Benefits
Ethernet networks make it easy to calibrate, configure and adjust process parameters
remotely, similar to how a printer driver works on a computer.
Smart devices can self-address and self-report their status, simplifying remote
troubleshooting and reducing maintenance costs and manpower.
Smart instruments with multiple capabilities reduce the number of devices required,
as well as the cost of programming, wiring and installation, lowering the total cost of
ownership.
Process data that lets you anticipate failures can improve predictive maintenance,
increasing uptime and reducing waste.
Getting better information faster, can help you improve process efficiency, increase
productivity and actually reduce the cost of innovation.
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Drawbacks
Intelligent instruments are not plug-and-play. While more information can be gathered more
accurately, enabling you to adjust processes more quickly, an intelligent control system can
also be more complex to manage and maintain.
Theres a steep learning curve for intelligent instruments. You have to be realistic. If your
control engineering staff isnt willing to move away from centralized decision-making or
your maintenance staff has a break-fix mentality, its unlikely theyll be willing to learn how to
manage and support the new systems.
Intelligent instruments also need to be properly installed. Follow vendor guidelines, install
devices correctly, validate your networks and update your cyber security methods. Otherwise,
youll be wasting your investment.
If this is your first attempt to use intelligent instruments, its best to select the vendor with
the broadest offering of applicable devices. Once your team has learned how to manage one
vendors instruments, it will be easier to learn anothers.
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Are Intelligent
Instruments The
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In one recent installation, a company invested $5 million in intelligent systems and was able
to save $27 million in expensive raw materials used in its production process. Those are the
kind of numbers that can attract the attention of the people who control the budgets.
What information is most important to gather for effective decision-making? Too much
information is just noise and can actually be a barrier to making process improvements.
Do you have industrial networks capable of handling the information flow to and from
smart devices?
Intelligent control systems cross multiple domains and require integration of people as
well as devices.
If your companys production processes are spread out over large areas or involve multiple
facilities with similar processes, the benefits from intelligent instruments can be even more
significant. Being able to remotely diagnose and fix devices, or replicate process improvements
multiple times in multiple locations can deliver big benefits to the bottom line.
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Managing Emissions
with Automation
By Jeanne Schweder
contributing writer
Automation World
Industries where emissions control is critical include electric utilities, oil and gas, chemical
processing, iron and steel, paper, food, mining, metals and cement. But emission control
concerns are not limited to these industries. Systems to control and reduce emissions are
required for any industrial process that produces sulphur and nitrogen dioxides (popularly
referred to as SOx and NOx), the major causes of acid rain, as well as airborne particulates and
volatile organic compounds (VOCs).
On the horizon are new regulations designed to limit mercury emissions in flue gas. These
rules will also apply to industrial facilities, including trash burners and industrial boilers, even
if they only generate process steam. More stringent controls on particulates will also require
new investments in emissions technologies.
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Managing Emissions
with Automation
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The list that follows touches upon the primary emission reduction methods used in industry:
Optimized process control is central to reducing NOx emissions from coal-fired power
plants. Oxygen is injected into the boiler to improve combustion and prevent pockets
of NOx from being created. A secondary technology, selective non-catalytic reduction,
or SNCR, injects urea or ammonia into the boilers, further reducing NOx emissions by
up to 20 percent. New low-NOx burners have also been introduced that allow a cooler,
more complete burn.
catalytic reduction, or SCR. This capital-intensive technology, which is viable only for
large coal-fired plants, involves very large reactors and again injects ammonia into the
flow. Automated systems measure NOx levels before and after the reduction process,
enabling operators to fine-tune the process.
Scrubbers, using either dry or wet processes, use automated systems that regulate
water flows, monitor pH levels and spray lime or apply a slurry of limestone to remove
95 percent or more of sulphur dioxide. A by-product of the scrubber process is calcium
sulphate, which is then used to make wallboard.
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Managing Emissions
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At the stack, the air from the process is passed over a rack of sensors that measure
oxygen, carbon dioxide and carbon monoxide levels, as well as sulphur dioxide,
sulphur trioxide and nitrogen oxide content.
Most air pollution control devices (APCDs) come as pre-built OEM packages that
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Whether your plant is processing food or chemicals, wastewater or steel, the process used
to audit your energy usage and find ways to use or waste less of it is much the same. Before
beginning your energy audit process, it is important to realize that, though there are
many energy saving steps that result in short-term payback, the average payback time for
investments to increase energy efficiency is five years. The older the facility and its equipment,
the greater the probability that the energy savings potentialand your return on investment
from corrective actionswill be significant.
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How to Conduct
an Energy Audit
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Look for steam or compressed air leaks. Are there improperly working natural gas regulators?
Does the plant have programmable thermostats? How energy-efficient are the lighting
fixtures? Do infrared scans detect any hot spots on the electrical equipment?
Also consider the energy efficiency value to be found in straightforward upgrades of existing
equipment. For example, have variable frequency drives been installed on motors serving
high-energy-consuming equipment, such as cooling towers? Older cooling towers, for
example, tend to have motors that run either slow or fast, with none of the gradients that
drives can provide to match energy consumption to different operating conditions.
Go beyond direct asset-related energy use and ask questions like: Is there lighting thats on
when no one is working in a room? Where are the large motor loads, and how and when are
they being operated? Are start times being staggered to avoid electrical peak power demand
surcharges? Is the plant subjected to extreme seasonal temperature fluctuations between
summer and winter?
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How to Conduct
an Energy Audit
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Steel plants, for example, are the largest consumers of electrical energy and also incur the
most frequent energy spikes because of their use of arc furnaces. The chemical and refining
industries, on the other hand, make greater use of compressed air and steam.
Draft a Pre-Plan
Once you have the initial findings from the walkthrough, draw up a pre-plan to address the
obvious areas of waste and identify the processes that consume the most energy. Most older
plants are poorly metered. If the only meter in the facility is the one measuring the main utility
feed, then it will be impossible to determine which machines or processes are contributing
the most to your utility bill.
The pre-plan should identify where meters are to be located to divide and measure energy
use among different processes. The information gathered from these sub-meters can then be
used to justify capital expenditures and enable you to develop a longer-term plan based on
where the best savings are for the least amount of investment.
Most importantly, make sure this plan focuses on the processes used to create the products
that contribute the most to the companys productivity and profitability. It should also define
a program of preventive maintenance to maintain energy-efficient production processes and
allow you to continue to innovate in the future.
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How to Conduct
an Energy Audit
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Corrective Actions
Companies are taking many corrective steps to increase their energy efficiency. Among the
most common:
Install variable speed drives to match power output with process requirements.
Take advantage of the software controlling motors to regulate equipment start-up
times and prevent unscheduled starts.
Install the most energy-efficient light bulbs and other lighting fixtures.
Apply automatic lighting controls that turn off lights when rooms are unoccupied.
Use programmable thermostats to match temperatures within the plant to operating
requirements.
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How to Conduct
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Changing our attitudes about energy consumption can change our behaviors and lead
to energy savings.
There are also more significant capital investments that can be made depending on
conditions at your facility.
With electricity rates high and natural gas rates currently low, it may make sense to invest in
gas-powered turbines. Justifying that kind of investment, however, requires an analysis of the
predictability of rates going forward. Further efficiency can be captured with a co-generation
system to produce steam as well as electricity, or even tri-generation if your processes require
hot water.
Another possibility is heat recovery. Investment in piping and heat exchange equipment can
allow energy to be passed from one process stream to another, reducing the load on utility
sources such as steam and cooling water.
How much you can expect to reduce your energy costs will vary from industry to industry and
plant to plant. No matter the savings potential at your facility, an energy audit is the first step
toward achieving your energy efficiency goals.
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The path to achieving energy efficiency is shaped as much by attitudes and organizational
skills as by the physical aspects of reducing energy demands. But its goals can never be
achieved without the automation technologies that make it possible to mine information and
control the operation of machines.
A 2009 study by the Aberdeen Group, a research and consulting firm, found that industry
leaders seeking to reduce energy consumption at their facilities viewed energy management
as strategic to their business success. The primary tools they applied in their endeavors
included advanced visualization, information collection and consumption monitoring.
Among the best practices adopted by industry leaders in reducing energy consumption and
costs, according to the study, are:
Making energy usage data available to decision-makers in real time. The faster changes
can be made to equipment operations, the greater the energy savings.
Taking energy costs into account when scheduling production. Peak demand charges
can account for as much as 60 percent of a companys energy bills.
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Energy Management
Best Practices
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Tying operational metrics to financial metrics. Its essential to understand how the costs
of energy for production and facilities affect the companys bottom line.
Since energy can constitute as much as 25 percent of a manufacturers operating costs, even
small improvements can have a dramatic impact on the bottom line.
Understand Consumption
From a practical perspective, any energy management initiative must start by gaining an
understanding of consumption patterns and cost sources from production processes and
facilities. Heres a go-to short list to kick off your initiative:
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Energy Management
Best Practices
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Prioritize Opportunities
By first attacking the low-hanging fruit, such as leaks in compressed air and steam systems,
lack of energy-efficient lighting and utility penalties for peak demand and reactive power,
youll gain some early wins at minimal cost. A next step can include installing sub-meters to
identify which production activities contribute the most to your energy bills.
Ultimately, prioritization means that you must first establish goals, and then phase in a
planned program of corrective actions. Heres an outline to follow as you establish your
priorities and ensuing goals:
fans in HVAC systems, motors are the biggest sources of industrial energy usage, as
well as waste. Adding variable speed drives will better match energy use to operational
requirements.
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Energy Management
Best Practices
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starts will help avoid peak demand penalties. Utility incentives for demand response
programs can be substantial. Automated controls ensure essential loads keep working
while minimizing costs.
lighting controls turn off lights when rooms or production areas are not in use. Match
illumination levels to task needs. Install energy-efficient bulbs and lighting fixtures.
P ower quality. If your plant is experiencing unexplained power outages and motor
failures, or paying penalties for reactive power, low power factor and harmonics may
be the cause. Upgrade capacitor banks or electrical equipment where necessary and
install corrective filters to extend equipment life.
E nergy management. Using software to track power quality, meter energy use,
and control remote monitoring systems will help you access energy information in
an organized fashion that speeds decision-making and lets you know where to take
corrective action.
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Energy Management
Best Practices
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Measure ROI
Energy management is not a one-time event. To achieve sustained savings requires a
proactive program of measurement, monitoring and preventive maintenance to make sure
that equipment and systems are working in optimal fashion. Periodically measuring the
progress achieved in reducing energy consumption and associated costs savings will build
support for continuing improvements. As you go about measuring your progress, keep the
following in mind:
The core takeaway of these tips is to realize that having a greater awareness of the cost
of energy is the first step in changing attitudes about energy consumption and related
behaviors in your facility. Following the best practices described above that have been
developed and implemented by other processing companies can favorably impact your
companys bottom line.
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The Impact of
Variable Speed Drives
By Marty Weil
contributing writer
Automation World
and
David Greenfield
Continuous processing facilities are finding increasing utilization for variable speed drives/
variable frequency drives (VSD/VFD) to control the motors on pumps, fans, conveyors,
etc. This is due to the reliability and low cost of an AC induction motor, as well as the high
performance of AC drives. Even though the up-front cost of an AC drive control unit is greater
than that of a DC drive, many factors quickly make up the difference. Conservative data
indicate a 17 percent savings as a percentage of total system and installation cost using AC
drives. Some end users have experienced up to 30 percent savings.
While energy usage savings are the primary factor for VSD utilization as utility costs continue
to increase, these savings are further supported by increased flexibility in selection of
product feed rates, improved accuracy for dispensing of materials, and an increase in access
to secondary process performance due to greater access to VSD parameters via control
networks.
Maintenance can become an issue if there is minimal to no in-house experience with VSDs,
however. But most of these concerns can be eliminated with comprehensive training of the
maintenance staff prior to project implementation, and reinforced by using the maintenance
staff during commissioning.
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The Impact of
Variable Speed Drives
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The Impact of
Variable Speed Drives
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of the dynamic reset limit option for the loops in the control system can automatically
prevent the process controller from outrunning the response of any type of final element.
For best performance, users should consider the following during the specification and
implementation of variable speed drive systems:
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Dave Woll
Vice President
ARC Advisory Group
and
David Greenfield
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IEC 61508 can seem confusing at first, because its underlying philosophy is new for
safety standards. Older, more conventional safety standards, stipulated specific rules and
specifications for making processes safe. IEC 61508 and its derivative standards, such as IEC
61511, departed from this approach by being more functional, or performance-based.
A principal aspect of this new approach to safety standards is that it leverages two
fundamental principles: safety lifecycles and probabilistic failure analysis. Unlike previous
standards that claimed to cover the entire lifecycle of a project, IEC 61508 and its offshoots
actually dofrom project conception to maintenance to decommissioning.
In essence, the standards specify safety lifecycle activities that need to be followed over
the entire life of a production system. Safety lifecycle management provides a method or
procedure that enables companies to specify, design, implement and maintain safety systems
to achieve overall safety in a documented and verified manner.
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Perform hazard and risk analysis: Determine hazards and hazardous events, the
sequence of events leading to hazardous condition, the associated process risks, the
requirements of risk reduction and the safety functions required.
Specify requirements for safety system: If tolerable risk is still out of limit, then
specify the requirements for each safety system and their safety integrity levels.
Design and engineer a safety system: Design system to meet the safety
requirements.
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Design and develop other means of risk reduction: Means of protection other than
programmable safety systems include mechanical systems, process control systems
and manual systems.
Install, commission and validate the safety protections: Install and validate that the
safety system meets the all safety requirements to the required safety integrity levels.
Operate and maintain: Ensure that the safety system functions are maintained during
operation and maintenance.
Modify and update: Make corrections, enhancements and adaptations to the safety
system to ensure that the safety requirements are maintained.
decommissioning a safety system. Ensure that the required safety functions remain
operational during decommissioning.
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Manage functional safety, safety assessment, and safety audit: Identify the
management activities that are required to ensure that the functional safety objectives
are met.
Plan and structure safety lifecycle: Define safety lifecycle in terms of inputs, outputs
and verification activities.
Verify safety system: Demonstrate by review, analysis and/or testing that the required
outputs satisfy the defined requirements for each phase of the safety lifecycle.
Activities for Phases I to III are typically carried out consecutively, while Phase IV runs
concurrently with the other phases. However, like all models, the safety lifecycle is an
approximation.
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Continuous process environments tend to be stable until theyre not. When that happens,
the consequences can be catastrophic. Think Deepwater Horizon.
The very stability of a continuous production process often induces a false sense of security in
operators. Lack of experience with system failure or unexpected alarms can lead operators to
freeze when systems suddenly cascade out of control.
Procedural automation standards originally developed for batch processes and discrete
manufacturing hold promise for helping continuous process operators deal more effectively
with sudden emergencies, as well as the more routine changes in state that can occur.
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Procedural
Automation for
Greater Safety and
Productivity
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Four IT Standards
You Should Understand
By Dennis Brandl
Chief Consultant
BR&L Consulting Inc.
Imagine a world without electrical standards, such as 110V at 60hz, or 220 at 50Hz, or a
world where every phone had a different type of connection and required a different type
of switchboard. Just as these standards are critical to the basic functioning of electrical
equipment, there are also IT standards used daily to ensure optimal functioning of production
systems in the process industries.
There are four production-related IT standards of special interest to the processing industries:
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continued
Four IT Standards
You Should Understand
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continued
Four IT Standards
You Should Understand
The new ISA 106 reports define the procedural control
strategy for continuous production during upsets,
switchovers, and other types of process changes.
Because these standards establish a commonly accepted
terminology, functions and process models by which
technical professionals are trained, and upon which solution
providers develop applications used in batch and process
production operations (as well as discrete manufacturing),
they should be of particular interest to those who are
new to the field and those who seeking a refresher on the
fundamentals of industrial processes.
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contributing writer
Automation World
and
David Greenfield
In most process industry facilities, the predominant means of communication between field
devices and control systems was, for many years, a 4-20 mA analog connection. Though this
connection method is highly dependable and still in use, the amount of wiring required is
substantial, as each device on the network must have its own separate connection to the
controller.
As digital technologies emerged on the industrial scene, the capability of fieldbus protocols
became a more attractive alternative to analog 4-20 mA communication because of the
reduced wiring requirements of fieldbus networks. Less wiring is required with fieldbus
because a fieldbus segment can carry both DC power and digital communication signals to
numerous separate devices over one fieldbus cable.
The predominant fieldbus protocols in the process industries are: Foundation Fieldbus, HART,
and Profibus.
As Ethernet more clearly becomes the network of choice, not just for the front office, but in
production areas as well, the move toward Ethernet-based communications in the process
industries is gathering a great deal of attention. Evidence of this can be seen in the increase
of end devices for process industry applications that now come standard with an Ethernet
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continued
Meet the DataMan 50L. The tiny barcode reader that brings
big performance to the food & beverage industry.
Dont let its size fool you. The DataMan 50L is huge in barcode reading performance.
Measuring just 23.5mm x 27mm x 43.5mm and featuring an IP65-rated housing, the
DataMan 50L is premium technology designed for 1-D-oriented barcode reading. The
DataMan 50L delivers read rates that can surpass 99% through Cognexs proprietary
Hotbars image-analysis technology.
The new DataMan 50L is a powerful upgrade for applications that use small laser
barcode scanner systems. Visit us at www.cognex.com/50L.
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Originally intended as a replacement for the 4-20 mA standard, Foundation Fieldbus can
be found in many heavy process applications such as refining, petrochemicals, and power
generation.
Two forms of Foundation Fieldbus are available, each uses different physical media and
communication speeds:
communication and power over standard twisted-pair wiring. Conforming with IEC
61158-2 (as does Profibus, detailed below), power can be delivered over the bus to field
instruments, while limiting current flows so that explosive conditions are not created.
subsystems, host systems, linking devices, gateways, and field devices using standard
Ethernet cabling. It doesn't currently provide power over the cable, although work is
under way to include this feature.
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continued
Think automation is
just another business cost?
Think automation is tactical
and not strategic?
Think no one has enough of the right
resources to execute your automation work?
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The rapid adoption of Ethernet on the plant floor over the past decade underscores the
need for more production information for better decision-making and the need to simplify
networks for easier access and maintenance. But just as there have been wars between
the varying fieldbus protocols over the years, a similar posturing over the capabilities of the
different protocols persists in the Ethernet arena.
To help you make sense of the main differences between six of the major industrial Ethernet
protocols, we turn a spotlight on CC-Link IE, EtherCAT, Ethernet/IP, Ethernet Powerlink,
Profinet, and Sercos III.
CC-Link IE
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Understanding the
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Industrial Ethernet
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CC-Link IE protocol fits at the transport network layer. It is not a TCP/IP or UDP-based
network. This is one of the reasons that its a separate protocol in order to guarantee
deterministic operation out of the box.
Frame format of the data is the Ethernet frame. Within the Ethernet frame is a CC-Link
IE frame with header and data information.
EtherCAT
The master does not require a special card to run EtherCAT, and each slave device
or node on the network has an ASIC or FPGA chip inside that implements the entire
protocol. The slave doesnt need a micro-controller or random access memory, which
means frames can be read and written as data goes through the network at a line
speed of 100 Mb/s with no switches built in.
EtherCATs fieldbus memory management unit uses logical addressing so that each
slave device knows where to find its data in the frame, regardless of its physical
location. One read-write cycle is capable of talking to all the devices without a great
deal of CPU overhead on the controller side.
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EtherCAT supports multiple scan rates and multiple acyclic data exchange rates on the
same network for use in multiple industrial automation processes including motion,
I/O, condition monitoring, and data acquisition.
to another protocol to the I/O level. This is due to use of LVDS (low voltage differential
signal) a third physical layer in addition to CAT 5 and fiber used to pass the EtherCAT
packets directly through all the I/O terminals so that each I/O terminal can be its own
independent node on the network.
EtherNet/IP
Safety aspects are addressed through CIP (common industrial protocol) Safety, which
allows safety devices to coexist with standard control devices on the same CIP network,
with or without a safety PLC. In this environment, safety sensors can operate alongside
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variable speed drives, safety controllers with standard PLCs and proximity switches.
Regardless of the combination of devices used, the integrity of the safety control loop
cannot be affected by any of the standard control devices.
Ethernet Powerlink
have to transmit the packet through every single station. When the system transmits
back, every node transmits the packet back as a broadcast. This makes it possible
to multiplex nodes, which means the node doesnt have to transmit its information
back on every single scan, allowing for network optimization and high-speed
synchronization.
By using a slot protocol, where each node has a certain slot time on the network and
passes data back to the master in a slot manner, this illuminates any collisions on the
system. This gives Ethernet Powerlink fast and predictable cycle times and also allows
for the removal and reconnection of nodes to the network without interrupting the
cycle.
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Redundancy is built in for ease of network recovery whether using a ring, star or daisy
chain topology. If any part of network is disconnected, the system will self recover and
report back that the network has gone down.
Ethernet Powerlink can be implemented via free download from Sourceforge.net. Its
based on C, so its transportable to controllers or PCs using a standard Ethernet port.
With that in place, any system can be connected to a Powerlink network and control
Powerlink nodes.
Profinet uses standard, unmodified Ethernet media, but does not use TCP/IP to
transmit real-time information. When real-time data is being sent, those two layers are
skipped. Diagnostic information, however, is accessed over TCP/IP.
Bumpless redundancy meaning that each node sends its message out in both
directions around the ring (when using a ring topology) to ensure at least one message
will always get through.
In depth diagnostics are available from the I/O rack level down to a module in that rack.
Profinet supports real time I/O for motion control as well as machine-to-machine,
controller-to-controller or peer-to-peer types of communication.
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Profinet allows for integration of other buses (including Foundation Fieldbus, Interbus,
ASI, HART, DeviceNet, and others) via proxies, allowing for maintenance of legacy
nodes.
permits a coordinated, centralized shutdown of devices during idle times. This means
that individual components or entire subsections of a plant can be switched off
automatically when not in use without the aid of external hardware.
Sercos III
Sercos III uses a tightly controlled time synchronization signal emitted from a master
control in the system once for every update cycle, providing nanosecond determinism
across the network. The time base is a phase-lock loop for deterministic control,
allowing for the synchronization of serially connected servo drives, CNCs, and motion
controls.
Each message sent from the control contains a master sync telegram for hard real-time
function. This also places fewer burdens on the host processors, freeing them up for
tasks such as running control algorithms and machine programs.
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The collective telegram approach underlying Sercos III means that each device places
its input data on common answer telegrams. During the remaining time in the cycle,
which for a typical application can be 80 percent or more of the available bandwidth,
any standard Ethernet protocol can be transmitted over the network.
Bumpless, single fault redundancy means that Sercos III nodes are specified to detect
broken links in less than 25 microseconds and immediately re-route telegrams back in
a double line configuration.
No telegram data is destroyed in a communication cycle over Sercos, thereby allowing
direct cross communication of data between slaves without the CPU burden or time
delay that a re-transmission of data by a master would impose.
Sercos III can be integrated with EtherNet/IP, allowing integrators to mix Sercos III,
EtherNet/IP and TCP/IP components within a single machine on a single cable.
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Wireless Trends
By David Greenfield
The history of wireless networking in industry has largely been that of cable replacement. It
was simply a tool to deliver communications in places where you simply couldnt run cable
for a variety of reasons. Maybe it was too expensive. Or maybe the cable would be running
in a hazardous zone. Through these types of applications, wireless secured a foothold in the
process industries over the past two decades.
Now we are beginning to see a shift in the types of wireless technologies used, as well as
different types of applications. This shift is coming from a user-needs perspective, rather than
from pure technological capabilities.
10%
15%
20%
>30%
26
19
18
2015
2011
0%
Source: WINA
14
22
64
13
6
7
10%
20%
30%
40%
50%
60%
70%
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you have not been able to collect that data before. Of course, this wouldnt make sense if you
had to dig a 1,000-yard trench and stop part of the plant for a couple of weeks while you did
Wireless Trends
that. But if you could easily put a wireless sensor in that part of the plant and do that very cost
effectively, thats effective incremental process measurement. Such small
Top Industry Applications For Wireless steps can certainly help you improve your efficiency and, when examined
from the aspect of a large process, like a refinery, there are huge overall
Asset Management / Condition Monitoring
58%
efficiency numbers involved in the end result.
continued
Control
Wireless sensors are, perhaps, the biggest area for substantial capital
expenditure savings in the process industries, especially when you think
about the potential benefit of establishing pervasive sensor networks.
When you literally start to put hundreds and thousands of devices out in the
facility or a refinery, that's when you begin to see real cap-ex savings versus
hard wiring. And this has already been documented. For example, using
temperature sensors positioned directly on the roller can produce a small
percentage of improvement in the surface finish of sheet steel by precisely
achieving the proper manifold temperature; this small improvement in quality translates into
millions of dollars in savings over the course of the process run.
44%
57%
30%
26%
13%
The third most prevalent trend for wireless technology is supporting mobile operators.
And its easy to see why: Removing the step of having to connect via an Ethernet jack as
measurements are taken at each stop is a big improvement in process.
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Following mobile in the fourth and fifth spots are voice/video data communications and
asset tracking. These types of wireless applications have been around for years and continue
to be deployed due to their successful track record, so its not surprising to see them among
the top trends.
What is surprising is the application that came in at number six in the 2012 WINA survey
control. This is surprising because wireless control had never even ranked in the survey prior
to this year. Now, however, 13 percent of survey respondents considered control to be their
top application of wireless. In industries like mining, wireless pump control has been around
for years, because there is no other way to really do it. But this result indicates that people
across industry are beginning to experiment with closed-loop control using wireless.
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If youre working in a facility without a great dealor anywireless sensors in place, you
may be suspicious about the viability of wireless sensor networks. To help illustrate how
ubiquitous wireless sensors have become across industry, following are a few examples of
wireless sensor deployments that have become so common that they could be considered
textbook application examples.
ireless limit switch networks are commonly used to prevent the
W
overflow of liquid storage tanks. Their operation is simple: As the tank fills
up, the fluid level forces a change in the position of the limit switch. The wireless limit
switch then sends a signal to the pump controller to start pumping out the tank to
lower the level. When the fluid level drops to a safe level, the switch then sends a signal
to the controller to turn off the pump.
general manager of the wireless business unit at Cooper Industries and chairman of the
Wireless Industrial Networking Alliance (WINA). We're doing a lot of work in Mexico
now to monitor and maintain oil pipelines, he says. In these applications, there is a
hierarchy of networking tools with sensor networks being used with instrumentation
on the pipeline itself to capture data and transmit it back to the control system
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Wireless Sensor
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Wireless Protocols
for the Process Industries
By Renee Robbins Bassett
Managing Editor
Automation World
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The principal difference between the two protocols is in the specification of the protocols
application layer. WirelessHART, for example, specifies HART as the application layer while
ISA100.11a leaves that layer undefined. This means that data in the application layer of
ISA100.11a can be transferred using Foundation Fieldbus, Profibus, Modbus, HART or other
protocols. While this makes ISA100.11a highly flexible, the customer must decide which
protocol to use. WirelessHARTs decision to specify only HART in the application layer was
done to deliver simplicity via use of a single data communication specification through the
network, meaning that data communication on the network is well-defined and understood.
Considering the potential for integrated use of the two wireless protocols, the obstacles
preventing a convergence seem to be more commercial than technical. Though the two
protocols are similar, investments have been made, vendors and early adopters are lined up
on either side, and product certification processes have been established. The two protocols
have been developed into products for sale. Marketing programs designed to win over
additional customers and vendor partners are in high gear. Both sides believe their approach
is right and others should come over to their way of thinking.
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contributing writer
Automation World
and
David Greenfield
As more operations aspects are tied to Ethernet networks and, therefore, are open to Internetbased access, the potential for greater collaborative operation and a freer work environment
increases. But so do the potential for security problems. Following are some basic tips and
considerations for achieving secure and reliable remote access:
1. Map out your project from the start. When companies fail to map out their
projects thoroughly from the start, they often find themselves saddled with applications
and automation products that dont work cohesively as a single system. Once you start
implementing various silosbe they applications or productsthings get more complex.
This is typical of problems that occur when automation products are implemented hastily,
without doing proper research, planning, or analyzing current and future goals, or without
realizing that implementing remote access monitoring for a facility is just step one of many.
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How to Avoid
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3. Understand users and roles. Understanding users and their roles can have
a significant impact on how the remote access strategy evolves. In most control systems
operations, the roles that may require remote access to control assets may include, but are
not limited to:
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complicated. Map out and document all acceptable access policies and procedures related to
allowable network access and coordinate this with industrial control system security experts.
Any user access that goes beyond simple viewing of data and permits changes to system
parameters should be extremely limited.
4. Know your vulnerabilities. Beginning at the remote user and following the
connection to the data or service, remote access can be compromised at any of the following
points:
T he users access device (laptop, PDA, etc.) can be attacked, compromised, and used to
access the control system network.
T he target system can be impersonated by an attacker to fool the user and thus gain
credentials or other information from the user system.
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A n attacker can impersonate a valid communications node and gain access to the
underlying communications medium.
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contributing writer
Automation World
and
David Greenfield
Recognizing that the biggest security risk to your control system assets are the operators who
interface with the system on a daily basis is the most important step to successfully securing
your systems. For a thorough analysis of your risks and setup of reliable control system
security technologies and processes, consult an industrial control system security expert such
as scadahacker.com, byressecurity.com, or industrialdefender.com. Following are the ground
level security steps that a continuous process facility should implement at a bare minimum:
1. Assess your systems. Compile an accurate list of all the assets in your plant: make,
model, and serial number. Where are your computers? Where are your PLCs? Its difficult to
secure something when you dont know it exists. This should be a high-level assessment in
which you go through your plant and figure out what is high risk and what is low risk, which is
determined by two key factors: how likely is a problem to occur? How serious is the problem?
For example, if something happened to your chlorine tank, it would be really ugly. That chip
pile, not so ugly. Get a feel for the significant risks. Where do you have to focus your effort?
The answer is going to drive your decisions and your capital allocation.
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Control System
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3. Start training. No one is going to follow policies unless they know about them and
understand why they are necessary. All levels of employees that interact with the control
system need to understand what an attack looks like and how to respond to one. You should
end up with a matrix of training for the various levels of users; it doesn't have to be onerous,
but it has to be done.
4. Understand your traffic flows. You need a diagram that shows all the things that
require intercommunication. Smart companies will have a comprehensive diagram showing
that the accounting department needs data out of this area, and maintenance needs data out
of this area, and so on.
6. Leverage safety reports. Those responsible for safety, when they do reports and
analyses, have done a good deal of the work needed to understand the security risks.
7. Use separate networks. Though this step is becoming less and less practical, some
still advocate that the process control network be kept separate from business networks,
and also isolated from the Internet. For this approach, which may not be viable in the longer
term, utilize operating system (OS) implemented security, with active directory domain group
security as the preferred approach.
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9. Use unique user accounts and passwords. All users should have unique user
accounts and passwords to minimize the risk of unauthorized access.
10. Provide port security. With this approach, the Ethernet MAC address connected
to the switch port allows only that MAC address to communicate on that port. If any other
MAC address tries to communicate through the port, port security will disable it. Most of the
time, network administrators configure the switch to send an SNMP trap to their network
monitoring solution that the ports disabled for security reasons. When using port security,
you can prevent unwanted devices from accessing the network.
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Most businesses in the processing industries have spent the past several years establishing
solid technology platforms and infrastructures to gather production data to improve
operations. The next step lies in intelligently using those technologies to foster better
decision-making, communication, and process improvement.
As an example of how this is actually occurring in industry, Joe Staples, head of
Manufacturing Systems North America for Bayer CropScience (Kansas City, MO), said that
Bayer CropScience has equipped its operators with Invensys Intellitrack mobile devices with
workflow software to direct them on how to safely perform the operations required of them.
During his presentation at The Automation Conference 2012, Staples said Bayer CropScience
is now looking to extend its use of mobile applications so that plant managers, engineers,
technicians, and maintenance can get the information they need at any time without have to
carry their laptops around or refer to a terminal or a PC.
Now the company is looking at extending its use of mobile applications so that plant
managers, engineers, technicians, and maintenance can get the information they need at any
time without have to carry their laptops around or refer to a terminal or a PC.
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Leveraging Analytics
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Mobile Workforce
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Core to this extension of the mobile workforce at Bayer CropScience is a push for greater
employee and operations connectedness through the use of analytics and communities.
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Leveraging Analytics
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shut the system down or not let it go to the next step until a properly trained engineer or
plant manager is there to review and give the go-ahead to move forward.
Community
Bayer CropScience is actively looking at using social media to help in its operations.
One of the questions theyre asking is: Why cant the machine participate in a social network?
After all, since those devices are now connected, they can provide information via a Facebook
page about its health and what its doing. And someone in maintenance at the facility can
access that information just as an engineer in another part of the world can.
Beyond ubiquitous communication and connectedness, Bayer CropScience is looking to use
social networks as a means to leverage its widely scattered technical resources for better
collaboration across the globe.
Benefits
These are the benefits Bayer CropScience is already seeing and expects to see more of from its
deployment of mobile devices to take advantage of analytics and community:
capturing the expertise of operators and dispersing it so that any operator can become
the best operator.
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B etter, more rapid focus on issues. By giving operators the information they
need to have, Bayer CropScience is creating a collaborative work environment among
all workers no matter where they are located. We can now collaborate on a global
basis to deal with issues that arise anywhere, said Staples.
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Automation as a Continuous
Improvement Tool for Everyone
By David Greenfield
Whether the term used is continuous improvement, Lean, Six Sigma or kaizen, most
discussions around these terms focus on how large, world-class companies have achieved
these cultural and procedural changes to improve their businesses. Often missing from the
discussion is how smaller operations, with far fewer resources, can adopt these practices for
significant benefit.
Chris Bacon, production manager at Pepsi Bottling Ventures (PBV) in Nampa, ID, described
how this small facility (which processes just one-tenth the amount of cases produced at PBVs
largest facility), leveraged automation technologies with real-time monitoring controls to
bolster a culture of continuous improvement.
Though this example originates in the batch process sector, PBVs approach to overall
equipment effectiveness (OEE) has lessons for continuous process as well.
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Automation as
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With these data now available, it was decided to disseminate select operational opportunities
to all employees and use improvement tools to support the overall goal of maintaining
high quality at the lowest cost. Armed with the new data and point-of-contact analysis, line
availability and final quality became areas for continuous improvement focus.
Line Availability
The original human machine interface (HMI) screens designed for the mix run filler were
cluttered and difficult to decipher. Without in-depth working knowledge of the system, it was
easy to lose track of the process flow. By remapping both machine centers in the HMI, the new
visuals more accurately captured the physical layout of the systems and improved real-time
process flow evaluation. To accomplish this, a simple color code scheme was mapped to relay
real-time processes. Green was used for gases, brown for syrup, and blue for water. This simple
redesign not only helped during the initial project, but has also allowed for expansion of the
HMI Designs
The new HMI visuals, using color-coded
schemes, more accurately capture
the physical layout of the systems
and improved real-time process flow
evaluation. Green is used for gases,
brown for syrup, and blue for water.
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Automation as
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facilitys trained knowledge base for support growing from one person to eight members
of the operation staff across all departments.
Furthermore, using Active Factory trending, analysis and reporting software from
Wonderware to determine the root cause of a recurring stoppage at both the mixer and the
filler, all rinse sequences for the mixer were changed to act only as event triggers (rather
than being time- or event-based, as they were in the previous system). This change not only
streamlined the programming process, but it eliminated any chance for one trigger sequence
starting ahead or at the same time as another, causing the reset status.
Another issue was the distribution of water between the filler and mixer during a flavor
changeover. In the original programming for the system, the mixer had to complete its rinse
before water could be sent to the filler, making it a highly inefficient symbiotic system. With
revised programming, both systems perform their end of run functions and rinse sequences
simultaneously.
Because of these modifications, a reduction of product changeover time from an average of
65 minutes in 2008 to 23 minutes in 2009 was achieved, exceeding PBVs initial 50 percent
reduction goal.
Quality
Leveraging OEE calculations for final quality proved to be a major issue, particularly with
regard to delivering first-time-through start-ups within specification for the product.
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To achieve this goal, it was necessary to establish a repeatable Brix:TA blend for products at
start-up. With scale timers being the most constant factor in the transfer of syrup from the
batch room to the mixer, using this measure proved the most logical approach. Once these
timers were established to ensure a match with proper product specification, the focus
moved to the actual blending of water and syrup within the mixer itself.
Because of multiple points in the piping that trapped water, offline testing determined that
it was necessary to enrich the syrup higher at start-up to compensate for the water that was
impossible to remove. Not wanting to waste more syrup than necessary, testing at multiple
points in the piping was performed to test Brix:TA to determine optimum enrichment ratios.
PBV Mixers
Mixers in use at Pepsi Bottling Venture
in Nampa, ID.
From this analysis, it was determined that exceeding OEM Brix set points by 9 percent for the
first 70 gallons of syrup, before allowing the recipe to default back to the original set point,
was the right approach.
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This calculation was based on analysis and measurement derived from piping length and
water left in the system. With these testing methods and trend analysis, first-time-through
start-up quality improved nearly 99 percent for all SKUs.
Bottom line: This PBV facility went from throwing away as much as 1,800 pieces of production
per run to, in most cases, throwing away zero pieces.
With an original project start date in late 2008 to design an integrated system for collecting
production data, PBV paid for the original project with the yield gains over time reduction
based on improved performance by mid 2009; they were also able to produce additional
products based on increased line availability.
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Combining OEE
and Automation
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Performance
Color-coded HMI
Color combinations on the HMI
screens correlate to real-time activities
of the line.
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Combining OEE
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Performance
To read more about ongoing
discussions surrounding the perceived
effectiveness of OEE, click here
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Results
Armed with this new production insight, one root cause for low performance at the PBV
facility was quickly identified the periodic jamming of a vacuum drum on the labeler. PBV
realized this problem because of the reason codes now built in to the downtime tracking
system.
With an OEM upgrade to the processor and a few creative internal modifications, PBV was
able to reduce downtime by 55 percent at this specific machine center. With this gain in
performance, the OEM upgrade was paid off in five months.
Long-term results with improved performance also exhibited a 43 percent decrease in labor
over time (from 2009 to 2011).
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contributing writer
Automation World
and
David Greenfield
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Four Considerations
for Upgrades and
Migrations
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Four Considerations
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for installation? For upgrades, its important to understand what the future outlook is for
the system under consideration. With the significant maintenance and security issues tied
to process control systems, you should always consider your risk of system obsolescence
and the associated costs incurred with such a scenario versus the costs of moving to a
better-supported system. The good news is that, in the process industries, most vendors
are very aware of the long-term use of their systems by end users and thus tend to support
their systems for multiple decades rather a single decade, as is more common with office
IT systems. As newer automation technologies become core components of process
control systems, be sure to talk with your supplier about their support plan for those newer
technologies.
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Cognex
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WEB: www.cognex.com
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Cognex
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S88 Builder
Demos
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Consulting Services
Electrical and Control
Design Services
Full Range of Project Delivery Services
Emergency and Contract Service
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MAVERICK Technologies
MAVERICK Technologies:
Continuous Process Optimization
No matter your industry, you can depend on MAVERICK Technologies for a range of services designed to
optimize your process. We work across all major platforms and deliver integrated process automation solutions
designed to meet your specific objectives and ensure future success. Our continuous process service areas include:
Strategic Manufacturing Solutions
Industrial Automation
WHITE PAPER
Maintenance Management
ERP for Manufacturing
Manufacturing Supply Chain
Strategic Engagements
VIDEO
bit.ly/Maverick_5
WEB RESOURCES
WEB: www.mavtechglobal.com
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Remote Management
Best Practices: How to
Utilize New Automation
Strategies
bit.ly/Maverick_4
WHITE PAPER
bit.ly/Maverick_3
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MAVERICK Technologies
Jim Bouler
phone: (850) 780-6477
EMAIL: james.bouler@mavtechglobal.com
LIVE CHAT: Click here to live chat with Jim!
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Winsted
Winsted
Winsted is a worldwide leader in control room console solutions. We
create attractive, ergonomic consoles that work with your operators
to improve comfort
and optimize
efficiency. We offer
stock, customized
and custom
consoles suitable
for any control
room application.
Whether you are
building a stateof-the-art control
room from the ground up, or simply need to upgrade your operations,
Winsted can provide the ideal solution. Our experts combine the
disciplines of industrial design, ergonomics and interior design to
create solutions that are both efficient and eye-catching. We give
special consideration to the ergonomic requirements of your operators
to build consoles that reduce fatigue, improve productivity and
COMPANY: Winsted
Products:
http://winsted.com/products.htm
WEB: winsted.com
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