Control

www.controleng.
com
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at A
io llie
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& f
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APR15 A&C Snipe (CE)_Layout 1 3/13/15 2:33 PM Page 1
, BIG features
Precise built-in data logging

Up to 32GB of information can be stored
and accessed locally via micro SD or remotely
accessed with the built-in web server.
eal-time data on temperature

and analog modules
Get the RIGHT information . . . RIGHT now!

Wiring diagrams, spec sheets and assembly
instructions are available simply by scanning
drop-down QR code tab on all I/O modules.
See for yourself!
Scan the QR code below.
FREE fully functional programming software
Productivity Suite software was developed and is supported

, GA headquarters. Designed to work easily and efficiently, it has been
industry-proven reliable by our customers for years.
Get more than you paid for . . .
www.Productivity2000.com
Order Today, Ships Today!
* See our Web site for details and restrictions. Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved.
1-800-633-0405
the #1 value in automation
Its time you get more than

you paid for in a PLC.
Introducing the
NEW
CPU
ONLY
$255
Affordable Innovation
Its not just the low price, but the incredible built-in
features that make our new Productivity2000 a
must-have controller.
Why pay thousands elsewhere for features
that are standard for our newest PLC,
including FREE programming software?
P2-550 CPU FEATURES:
AutomationDirect
CPU and I/O

Comparison
High-resolution
4 line by 10 character
OLED diagnostic display
50MB built-in memory
Removable micro SD slot
USB programming port

RS-232 port
RS-485 port
10/100 Ethernet port
10/100 Ethernet port
Three industry-standard
communications protocols
Up to 32GB of data storage per card
MULTIPURPOSE
Allen-Bradley
Productivity2000
CompactLogix
Base (if required)
$69.00
N/A
Power Supply
$69.00
$414.50
CPU
$255.00
$3,160.00
16 AC Inputs
$105.00
$286.00
16 24VDC Inputs
$69.00
$244.00
8 Relay Outputs
$51.00
$301.50
8 Analog Input
Channels (mA)
$199.00
P2-08AD-1
1769-IF8
ASCII Comm Module
$0.00
$737.00
Modbus RTU
Comm Module
$0.00
$701.00
Total System Price with

USB, Ethernet and Serial
$817.00
$6557.50
P2-04B
P2-01AC
P2-550
P2-16NA
P2-16NE3
P2-08TRS
Built in to CPU
Built in to CPU
N/A
1769-PA4
1769-L33ER
1769-IA16
1769-IQ16
1769-OW8I
$713.50
1769-ASCII
1769-SM2
All prices are U.S. published prices. AutomationDirect prices as of 6/5/2015.

Allen-Bradley retail prices taken from www.plccenter.com 5/12/2015.
Plus the Productivity2000 features:

Effortless PID loops
Flexible tag name
programming
Auto-discovered I/O
Hot-swappable modules
Simple VFD conguration
Built-in data logging
Web server functionality
REMOTE I/O GS DRIVES only
Modbus
Get more than you paid for . . .
www.Productivity2000.com
input #1 at www.controleng.com/information
Order Today, Ships Today!
* See our Web site for details and restrictions. Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved.
1-800-633-0405
the #1 value in automation
Productivity2000 - small size

Shown at actual size: power supply, CPU and seven I/O modules in only 10-1/2
Rea
FR
ETHERNET
micro SD
USB
RS-232
RS-485
Dont let the small size fool you, the Productivity2000 is a robust controller that includes many
impressive features in its compact design. From tag name programming, to auto-discovered hardware including VFDs, to web capabiltiy and mobile device access. There is really no way to discuss
them all, so head on over to our website, www.Productivity2000.com to get the full story.
Hardware that is built to last
Engineered here in the USA, the Productivity2000s rugged design and quality-tested build is ready
for eld duty. We stand behind its performance with a 2 year warranty. Not only can the P2000
handle adverse conditions, but the 50MB of user memory also ensures that it has enough processing power to accommodate any future expansions you may need. A small investment today
can grow with your application needs tomorrow.
Our P
at our Atlanta,
SEPTEMBER 2015
Vol. 62
Number 9
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
25
Features
25
26
28
30
33
34
36
35
26
Cover photo courtesy: Bosch Rexroth
34
Flexible packaging-machine design

Cover story on packaging automation: All industries need control-system flexibility, code re-use, scaling, and lower cost.
Pneumatic valve technology

Packaging automation: Select manifold valves with a compact, lightweight design and digital electronics for easy
integration into automation controls platforms and maximum value. See more online.
Servos improve packaging machines

Packaging automation: Upgrade your next machine design with servo motors to decrease downtime, decrease
footprint, increase throughout, and two other key reasons. See more images online.
Software licenses, upgrades

Industrial software users should use new features and innovations without costly annual software maintenance
contracts or paying for each individual software version release. See related Digital Edition Exclusives.
Managing the risk of IoT

Internet of Things (IoT) is growing rapidly. More devices are going online. Security is required to protect devices and
users. Industrial network design and best practices help, including six steps for IoT risk mitigation. See more advice in
the Digital Edition.
Hybrid machines, standard CNC

Additive manufacturing: As the era of additive and subtractive machine tools emerges, todays controls are well
suited to handle the challenges, says a provider of CNCs and training. See related Digital Edition Exclusive.
Engineering Leaders Under 40

These 2015 award-winning Leaders, a dedicated group of engineers, give hope to manufacturings future.
Digital Edition Exclusives, www.controleng.com/DigitalEdition:

Nine articles: Metal for 3D printing; SOFTWARE: Specification documents; Gateways; IIot software delivery; Legacy software;
PLANT-WIDE ETHERNET: Ethernet network health; 40% capacity increase; Networks for Industry 4.0; IoT risk
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 62, No. 9, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher
/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2015 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license.
Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@cfemedia.
com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses
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GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription
mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. 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.
SEPTEMBER 2015 CONTROL ENGINEERING www.controleng.com
Re-Route Your Temperature Measurements

Around Potential Roadblocks
The new THZ3/TDZ3 Dual Input Smart HART
temperature transmitters can help you avoid costly
process interruptions and maintenance delays by
ensuring your measurements always make it safely
to your control system. Our Sensor Backup and
Failover protection feature means you will never
miss those critical readings - even if something
goes wrong with one of the sensors.
Plus, with Device Intelligence, a series of new and
advanced features that enable smarter control
and monitoring, the THZ3/TDZ3 gives you the
condence that your temperature measurements
will get from Point A to Point B despite any potential
roadblocks.
Demand Moore Reliability
To learn more about our Dual Input

p Temperature
p
www.miinet.com/THZ3TDZ3
Transmitter, go to:
900
Or call 800-999-2900
SEPTEMBER 2015
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
INSIDE PROCESS
appears after page 45; If not, see the Digital edition: www.controleng.com/DigitalEdition
P1 How to update an HMI
Upgrading human-machine interface (HMI) hardware, software, and

applications can be an efficient process with limited required development
time if these recommendations are followed.
P8 A better way to install automation

in classified areas
Instead of employing protection methods, its often better to move

automation systems to less hazardous areas and to use components
rated for use in these locations.
PRODUCT EXCLUSIVE
departments
news
8 Think Again
Cyber-physical systems, saving
children, 5G
18
Giving robots a more nimble

grasp
20
Control panel standards are

changing soon; Industry 4.0
group looking to expand
21
Standards group on counterfeit

pharmaceutical packaging
22
Events, Online news
10 Apps for Engineers

Control methods
12 Products Exclusive
All-in-one compact PLC controller
PRODUCTS
14 Research
Workforce development: Unskilled
workforce struggle
products
16 Control Engineering
International
62
Chinas Industry 4.0

implementation
64 Back to Basics
Software integrates remote I/O

capability; Industrial router for
remote machine connection,
commissioning; Surge protection
devices for industrial applications
WLAN design basics,

considerations
www.controleng.com
CONTROL ENGINEERING SEPTEMBER 2015 5
More resources posted daily at:
SEPTEMBER
Trending
www.controleng.com
New Products
Control Systems
Process Manufacturing Discrete Manufacturing
System Integration
Networking & Security
Info Management
Education & Training
2015 Industrial
Internet of Things (IIoT)
webcast series
Control Engineerings webcast series
continues in September and covers
several topics on the Industrial Internet of
Things. Learn more about these upcoming webcasts here www.controleng.com/
media-library/webcast-archive.html:
lloT webcast two: Operations
Thursday, Sept. 17, 2015, at 11 a.m.
PDT/1 p.m. CDT/2 p.m. EDT
IIoT webcast three: Integration considerations
IIoT video: See on-machine sensor values in

real time via Apple iPad
Theres a lot more to read online. Go to www.controleng.com/news to read
Control Engineerings exclusive web content:
Career advice for an engineering student
Security for wireless instrumentation
WLAN design basics and wireless network consideration
Time for OT, IT to align priorities
Prevalence of IoT may leave networks vulnerable to attacks
Join the conversation online at www.linkedin.com/groups?gid=1967039:
Various types of PLC
Thinking of a project in automation or industrial robotics for my final year...
any suggestions?
Why you need NO timers, other than ON DELAY!
System Integration
Keep up with the latest industry news by subscribing
to Control Engineerings 14 newsletters at
www.controleng.com/newsletters. SI advice includes:
Project management tips for system integration
Creative teamwork
Gateways for the Industrial Internet of Things
Point, click, watch

DIGITAL FITNESS: Tips & Tools for Trimming
the Digital Fat in 2015: Steve Krull
Marketing to Engineers: The digital landscape is constantly
changing with new strategies emerging all the time. Join Steve
Krull of Be Found Online for what promises to be an entertaining
session covering some of the things you can do to get your site,
content and campaigns in tip top shape for 2015, and increase
your business. www.youtube.com/user/ControlEngineeringTV.
Tuesday, November 3, 2015, at 11 a.m.

PDT/1 p.m. CDT/2 p.m. EDT
Other webcasts are archived, including
cyber security, project management,
Ethernet, and wireless.
Oil & Gas Engineering

August issue
Oil & Gas Engineering helps to maximize
uptime and increase
productivity with industry
best practices and new
innovations, increase efficiency from the wellhead
to the refinery with automation and monitoring
strategies, and maintain
and improve safety. At
www.oilandgaseng.com:
Operational technology to information
technology in the oil and gas industry
The Internet of Things (IoT) in the oil
and gas industry
Engineering career
advice from the 2015 Control
Engineering salary survey
Think again: Many subscribers taking the
2015 Control Engineering salary survey
provided write-in advice about engineering careers. Keep learning and mentoring and learn effective project management and communications, including
the benefits of automation and controls
engineering, are among tips and reminders. Get some advice at
www.controleng.com/ce-research.
Unbeatable Control,
Precision, and Flexibility
Lowering cost, increasing productivity, and shortening design times are just some
of the challenges industrial engineers face. The graphical system design approach
combines productive software and reconfigurable I/O (RIO) hardware to help you
meet these challenges. This off-the-shelf platform, customizable to solve any control
and monitoring application, integrates motion, vision, and I/O with a single software
development environment to build complex industrial systems faster.
>> Accelerate your productivity at ni.com/industrial-control-platform
800 453 6202

2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.
Other product and company names listed are trademarks or trade names of their respective companies. 12125
NI LabVIEW system design

software offers ultimate
flexibility through FPGA
programming, simplifies
code reuse, and helps
you program the way you
thinkgraphically.
editorial
THINK AGAIN
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523

630-571-4070, Fax 630-214-4504
Content Specialists/Editorial
Cyber-physical systems,
saving children, 5G
Automation, controls, and instrumentation are

used for cyber-physical integration, saving children,
and developing technologies for 5G wireless
communications. Get inspired.
ts hard not to be inspired about engineering after viewing demonstrations of the

cyber-physical worlds that could help
manufacturers and machine designers to
be more efficient, a heart pump thats saved
more than 800 children since U.S. Food and
Drug Administration (FDA) approval, and
5G wireless data transfer technologies under
development shown to move 10 GB per second. These were among on-stage keynote
demonstrations at the NIWeek conference in
August 2015 in Austin, Texas.
With data collection, more channels and
faster sampling are the trend driving more
data. More data provides more opportunity
to drive improvements and business results,
but we cannot just connect sensors to the
cloud and use the information. Innovation is
required in-between. Edge analytics are needed to put control right next to measurement,
explained Eric Starkloff, executive vice president of global sales and marketing, National
Instruments (NI).
Ride the technology wave
Moores Law wasnt a law, it was a selffulfilling goal, Starkloff said. Companies
need to take advantage of the next incredible
wave of technology, he said, and many are.
An Industrial Internet of Things (IIoT)
demonstration used a mountain bike fitted
with sensors and instrumentation. Software
from ThingWorx, a PTC business, showed
how an operator might see an industrial
machines metrics in real time by looking
through a mobile human-machine interface
(HMI) or wearable HMI, such as a headmounted, hands-free display.
Berlin Heart Inc. created a heart assist
device for children, which can assist heart
pumping until the child can get a transplant
or heal. Before use, testing simulates a heart
to verify electrical and pressure settings for
proper calibration.
An automated sod-harvesting machine
from Firefly Equipment, the ProSlab 155, has
8
an advanced design and control system, 40

hydraulic control valves, 5 axes of motion,
and more than 150 I/O channels for more
accuracy and less maintenance, securely.
A security enhanced Linux kernel (being
applied in the Airbus factory of the future
with more robotics, smart tools, and coordinated interfaces), in cooperation with system
integrator Leccionne, requires specific calls to
the kernel to ensure that certain operations are
from a secured source.
Big data: Noting that companies
only analyze 5% of data collected, Jaguar
increased the amount of data it examines
from less than 10% to more than 95%, to
decrease time to market and maintain quality.
Nokia, in testing for 5G cellular service
under development, proved millimeter wave
spectrum as viable for use, in a 2x2 multiple
input multiple output (MIMO) link at 10
Gbps, more than four times better than last
year. Samsung is working on full-dimension
MIMO (FD MIMO) to increase capacity 3x
to 5x, with 3-D waving forming to point the
signal where needed.
A vector signal transceiver was used
by Noffz and Harmon to speed testing and
decrease emergency response time to an automobile wireless notification system by 40%.
Too busy to travel? Think again: Conferences deliver inspiration and information. ce
More advice
Share inspiration from a conference by using the
comment feature of this posted article.
See 10 photos and more details, with insights
from NI co-founders.
Link to a robotic exoskeleton from Hyundai Motor
Group.
Browse events, www.controleng.com, upper right.
Mark T. Hoske, Content Manager

630-571-4070, x2214, MHoske@CFEMedia.com
Peter Welander, Content Manager
PWelander@CFEMedia.com
Amanda Pelliccione, Director of Research
630-571-4070, x2209, APelliccione@CFEMedia.com
Joy Chang, Digital Project Manager
630-571-4070 x2225, JChang@CFEMedia.com
Chris Vavra, Production Editor
CVavra@CFEMedia.com
Eric R. Eissler, Oil & Gas Engineering, Editor-in-Chief
630-571-4070 x2224, EEissler@CFEMedia.com
Contributing Content Specialists

Frank J. Bartos, P.E., braunbart@sbcglobal.net
Jeanine Katzel, jkatzel@sbcglobal.net
Vance VanDoren, Ph.D., P.E., controleng@msn.com
Suzanne Gill, European Editor
suzanne.gill@imlgroup.co.uk
Ekaterina Kosareva, Control Engineering Russia
ekaterina.kosareva@fsmedia.ru
Marek Kalman, Poland Editor-in-Chief
marek.kalman@utrzymanieruchu.pl
Luk Smelk, Czech Editor-in-Chief
lukas.smelik@trademedia.us
Aileen Jin, Control Engineering China
aileenjin@cechina.cn
Publication Services
Jim Langhenry, Co-Founder/Publisher, CFE Media
630-571-4070, x2203; JLanghenry@CFEMedia.com
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Letters should include name, company, and address,
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Its About (up)Time.
Upgrade to More Uptime.

When you choose a PROFINET network, the comprehensive diagnostics are baked in the protocol.
PROFINET diagnostics uniquely help prevent and reduce unplanned downtime. Scalable network redundancy
is as easy as running the cable. Because its about time.
Welcome to The PROFINET of Things...Weve Been Waiting for You.

apps for
ENGINEERS
www.controleng.com/appsforengineers
Automation Solutions for

End of Line Packaging
& Food Processing
Industries
Control methods
CFE Medias Apps for Engineers is an interactive
directory of engineering-related applications for
Apple iOS and Android operating systems from
various companies. Weve categorized apps
by category, company, and type. These energy
management and savings applications are listed
in the app as of September 2015.
EZ-RMC
iOS 6.0 +, Android 4.0.3 +
Cost: $25.99
Company: EZAutomation
Website: www.ezautomation.net
EZ-RMC allows users to remotely connect to selected EZAutomation humanmachine interfaces (HMIs) and view and operate the currently displayed screen
on the remote HMI. Currently supported HMIs:
- SoftHMI ver i.12.4 or later
- EZWindowsHMI ver i.12.4 or later
- EZ-CE HMI ver i.12.15 or later
ISWvis Mobile
Android 2.3.3+
Cost: Free
Company: ISW
Website: www.iswvis-mobile.at/en
ISWvis Mobile is graphical software for visualization and control, or supervisory
control and data acquisition (SCADA/HMI), for Simatic S7 (S7-1200, S7-300,
and S7-400) and the Siemens Logo controls for Android. Use the PC Editor to
create and transmit visualizations on an Android smartphone or tablet to ISWvis
Mobile. See and operate control(s) over wireless local area network (WLAN) and
virtual private network (VPN).
JUMPFLEX-ToGo
Android 2.2+
Cost: Free
Company: Wago
Website: www.wago.us
Visit us at Booth #6104

South Hall
Jumpflex-ToGo brings the power of PC-based configuration software to a

mobile device. Configure input and output parameters via a smartphone or
tablet PC on an Android OS via a finger swipe for 857 Series transducers. View
configuration data and the actual measured value. The Wago 750-921 Bluetooth
adapter will communicate between a smart phone and transducer.
Lutron Home
Varies with device
Cost: $19.99
Company: Lutron
Website: www.lutron.com
Global manufacturer of process control

and factory automation solutions
Control lights, shades, temperature, keypads, and more from anywhere. Set
a comfortable temperature when returning from a trip, ensure lights arent left
on, and shades arent left open while youre away. Manage multiple RadioRA 2,
HomeWorks QS, and HomeWorks Illumination systems in the same app.
For more information:

Call: 1-800-Go-Festo
1-800-463-3786
www.festo.us/packaging
10
Reliable Detection
For Your Application
You cant afford not to know. See it all at thinkallied.com/sensors
1.800.433.5700
Allied Electronics, Inc 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
EXCLUSIVES
product
All-in-one compact PLC controller

Unitronics Vision700 is an all-in-one compact programmable
logic controller (PLC) with an expansive 7-in. color touchscreen
with a variety of input/output (I/O) modules and expansion
options and can use both snap-in I/O modules that plug directly
into the unit and DIN-rail mounted I/O expansion units.
nitronics Vision700 is an all-in-one compact programmable logic controller (PLC) with an expansive 7-in.
color touchscreen with a variety of input/output (I/O)
modules and expansion options. The PLC offers a wide range
of I/O configurations that can include digital, high-speed, and
analog I/Os modules, as well as PT100/thermocouple and
weight/pressure measurement. It can use snap-in I/O modules that plug directly into the unit and DIN-rail mounted I/O
expansion units. Expansion modules enable 1,000 I/O points
locally or remotely at distances of up to 1,000 m. Communication options include Ethernet, cellular, and industrial protocols such as Modbus, DF1 slave, BACnet, J1939, CANopen,
and others. Each unit comes supplied with an Ethernet card
and USB programming port; an additional RS232/RS485 port
can be added for Profibus and CANbus communications. It
features the Protocol utility, which allows it to communicate via almost any ASCII protocol. The PLC can be accessed
I want
safety
straight
out of
the box
via the programming port or remotely accessed using GPRS/

GSM/CDMA and other IP networks for data acquisition and
program download. It can notify supervisors of critical information via e-mail and short-message service (SMS), enabling
real-time remote management. It uses intuitive, all-in-one
VisiLogic software, designed to enable hardware configuration, PLC, and HMI application programming. The software
has a full library of drag and drop function blocks for complex automation control tasks. ce
Unitronics, www.unitronics.com
Input #200 at www.controleng.com/information
Go Online
www.controleng.com/products has more products. Also see the product
section in the September 2015 print/digital edition.
Interested in introducing a product to the world here?
Contact Mark T. Hoske, mhoske@cfemedia.com.
Introducing the One Series

Safety Transmitter
Now plant safety pros get simple setup and faster,
safer performance, right from the start all
at a more affordable price. Instead of a costly,
overcomplicated process transmitter that must
be adapted for safety use, the One Series Safety
Transmitter is the first SIL-certified transmitter
designed solely for safety system applications.
Only the One Series Safety Transmitter comes
with an internal high-speed switch for the fastest
emergency shutdown. And that simple design
means fewer nuisance trips for greater safety,
productivity and throughput. Drop in the One Series
Safety Transmitter and your safety work is done!
LEADERS IN SAFETY, ALARM & SHUTDOWN
www.ueonline.com/st
Poultry Proven.
BaldorDodge Quantis Ultra Kleen and Tigear-2

Ultra Kleen stainless steel gear reducers are the
ultimate choice for poultry and meat processing
applications. Completely sealed and made of premium
stainless steel, each gear reducer features long-life
gear construction, maintenance-free operation and
IP69K rated protection against high pressure and high
temperature washdown environments.
You can count on Quantis Ultra Kleen and Tigear-2
Ultra Kleen stainless steel gear reducers for the
superior reliability it takes to survive harsh washdown
applicationsday after day after day.
Call. 800-526-9328
Click. www.MotionIndustries.com
479-646-4711
Visit. Overbaldor.com
550 Locations
Premium Stainless Steel
Maintenance-free
Rounded Surfaces Prevent Water Pooling
IP69K Rated Protection
@BaldorElectric
Follow the story #PoultryProven
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2015 Baldor Electric Company
Ethernet technology
budget allocations
Products, software
Don't know
research
26%
2015 WORKFORCE DEVELOPMENT STUDY:
Five findings on the

unskilled workforce struggle
espondents to the CFE Media

2015 Workforce Development
Study identified five high-level
findings impacting the manufacturing
industries today:
1. Workforce shortage: The average manufacturing facility today has 5%
of jobs currently unfilled, down from 7%
in 2014. Despite the decrease, 64% of
respondents still believe that their facilitys workforce shortage will increase over
the next 3 to 5 years.
2. Causes: When asked about the
primary causes of the workforce shortage, 56% of respondents said there arent
enough skilled applicants to fill the roles
of the growing number of retirees, and
another 34% agree that their hiring rates
arent keeping up with manufacturings
rapid expansion.
3. Unskilled workforce: According to
respondents, the younger workforce most
lacks problem solving (57%), instrumentation (55%), project management (51%),
and electrical knowledge (50%); but they
remain proficient in computer knowledge
(60%) and other basic skills (31%).
4. Actions taken: In an effort to

combat the workforce shortage, 44% of
facilities have taken to online recruitment and job postings, 40% have instituted or increased in-house training, and
35% have reached out to local technical
schools for assistance. Nine in 10 respondents believe that their facilities still need
to increase internal education/training
programs and provide clear career paths
for each new employee in order to better
appeal to the younger workforce.
5. Manufacturings image: More
than half of respondents still dont believe
that manufacturing is portrayed as a positive career choice in the U.S. Sixty-three
percent agree that offering apprenticeship
programs would help to improve manufacturings image, and another 57% think
introducing this career choice at an earlier
education levelas well as improving
salaries, benefits, and job securityare
key action items.
View more information at
www.controleng.com/2015WorkforceDevelopment.
Amanda Pelliccione is research director at
CFE Media, apelliccione@cfemedia.com.
Outsourced functions as result of workforce shortages

40%
4
Maintenance
e
2
28%
Engineering
1
17%
T
Manufacturing IT
Human resources
1
10%
Otherr
1
10%
e
None
2
27%
Maintenance and controls and automation are the most outsourced functions. Graphics courtesy: Control Engineering, CFE Media.
www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION
45%
16%
About
the same
S i
Services
64%
of survey respondents perceive their control system cyber security threat level as
low to moderate. Source: Control
Engineering 2015 Cyber Security
Study
7 in10
end users
expect their base annual salary
to increase this year; average
increase expected is 3%. Source:
Control Engineering 2015 Career
Survey
66%
of survey respondents claim that the lack of available skilled workers has not kept
their facilities from expanding
operations. Source: CFE Media
2015 Workforce Development
Study
3
37%
Controls, automation
14
13%
More research
Control Engineering surveys its
audience on five topics each
year: cyber security; career survey;
system integration; information
integration; and mobility, Ethernet,
and wireless. All reports are available at
www.controleng.com/ce-research.
INTERNATIONAL
Made in China 2025:
Chinese government aims

at Industry 4.0 implementation
The Made in China 2025 plan, known as the Chinese version of Industry 4.0, proposes
four specific measurements to assess industrys Industry 4.0 maturity.
T
Aileen Jin
Editor-in-chief,
Control Engineering
China
he Made in China 2025 plan, known

as the Chinese version of Industry 4.0,
was printed and distributed by the State
Council in 2015, symbolizing progress
from the proposal of the concept to the implementation of the plan. The Made in China 2025 proposes a target of becoming a manufacturing giant
within 10 years. During these 10 years, companies
should achieve significant improvement in overall
manufacturing quality, enhancement of creativity
and productivity, and the integration of industrialization and information.
The plan stipulates that the percentage of
research and development (R&D) funds of large
manufacturing companies should increase from
0.95% in 2015 to 1.68% by 2025, and the valueadding ratio of the manufacturing sector should
increase by 4%. Use of computer numerical controls (CNC) should increase 30%, and the energy
consumption of manufacturers should fall 34%.
The plan also proposes nine strategic missions, five key projects, and 10 breakthroughs in
key sectors with respect to the implementation of
the greater plan of transitioning from a manufac-
turing country to a manufacturing giant. The five

key projects include the construction of manufacturing innovation centers, smart manufacturing
projects, manufacturing base strengthening projects, green manufacturing projects, and high-end
equipment innovation projects.
Recently, the Chinese Ministry of Industry
and Information Technology (MIIT) released the
2015 smart manufacturing projects, including
94 projects covering scientific research institutions and enterprises incorporated into the list,
symbolizing the start of the smart manufacturing
project in the Made in China 2025 plan. ce
- Aileen Jin, editor-in-chief, Control Engineering China. Edited by Joy Chang, digital project manager, Control Engineering,
jchang@cfemedia.com.
Go Online
Read this online for more details. This was translated and
edited for Control Engineering from Control Engineering
China. www.cechina.cn
See other international coverage.
www.controleng.com/international
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NEWS
Giving robots a
more nimble grasp
Most robots on a factory floor are fairly ham-handed:
Equipped with large pinchers or claws, they are designed to
perform simple maneuvers, such as grabbing an object and
placing it somewhere in an assembly line. More complex movements, such as adjusting the grasp on an object, are still out of
reach for many industrial robots.
Engineers at MIT have now
hit upon a way to impart more
dexterity to simple robotic grippers, by using the environment as
a helping hand. The team, led by
Alberto Rodriguez, an assistant
professor of mechanical engineering, and graduate student Nikhil
Chavan-Dafle have developed a
model that predicts the force with
which a robotic gripper needs to The robot pivots the rod
push against various fixtures in between its fingers by pushing
the environment in order to adjust against a bookend. Courtesy:
Alberto Rodriguez, Nikhil Chaits grasp on an object.
If a robotic gripper aims to van-Dafle, MIT/MIT News
pick up a pencil at its midpoint,
but instead grabs hold of the eraser end, it could use the environment to adjust its grasp. Instead of releasing the pencil and
trying again, Rodriguezs model enables a robot to loosen its
grip slightly and push the pencil against a wall, just enough to
slide the robots gripper closer to the pencils midpoint.
Rodriguez calls these improvements extrinsic dexterity
as opposed to the intrinsic dexterity of, say, the human hand.
To adjust ones grip on a pencil in a similar fashion, a person,
using one hand, could simply spider-crawl her fingers towards
the center of the pencil. But programming such intrinsic dexterity in a robotic hand is tricky and raises a robots cost. With
Rodriguezs approach, existing robots in manufacturing, medicine, disaster response, and other gripper-based applications
may interact with the environment to perform more complex
maneuvers cost-effectively.
Chasing the human hand is still a very valid direction [in
robotics], Rodriguez said. But if you cannot afford having a
$100,000 hand that is very complex to use, this [method] brings
some dexterity to very simple grippers. Rodriguez and Chavan-Dafle will discuss the new approach this month at the International Conference on Intelligent Robotics and Systems.
Giving robotics a push
Visit omega.com/
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COPYRIGHT
INCALL
ALLRIGHTS
RIGHTSRESERVED
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COPYRIGHT 2015
2011 OMEGA
OMEGA ENGINEERING,
ENGINEERING, INC.
The team is seeking ways a robot might use gravity to toss

and catch an object, as well as how surfaces like a tabletop may
help a robot roll an object between its fingers. Research was
supported, in part, by the National Science Foundation. This
article online has more details: www.controleng.com.
- Edited from an MIT News Office story by Jennifer Chu
by Chris Vavra, production editor, Control Engineering,
cvavra@cfemedia.com.
Prices listed are those in effect at the time of publication and are subject to change without notice. Please contact OMEGAs sales department for current prices.
Note: Models with wireless option are approved for use in the U.S., Canada and Europe only.
18
SEPTEMBER 2015 CONTROL ENGINEERING
Independent High Integrity safety.

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system that is integrated with ABBs System 800xA DCS can now be interfaced
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(Harmony and Melody) or our heritage technologies (Advant, MOD 300) as well
as 3rd party control systems, PLCs or simple HMIs. Independent High Integrity is
the perfect SIL3 certified safety system; when you need safety independent of the
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NEWS
industry
Control panel standards

are changing soon
Theres a transition underway regarding UL 508 of which customers and control panel builders should be aware: UL
508 will soon be phased out and replaced
by UL 60947-4-1. This change is the
result of more than 10 years of work by
the UL, National Electrical Manufac-
turers Association (NEMA), and others.

The purpose is to harmonize international standards from UL and its counterparts
such as the Canadian Standards Association (CSA) and the International Electrotechnical Commission (IEC) in Europe.
The UL 508 standard is more than
200 pages long, and the committee that
was formed to update this standard went
through each page, paragraph by para-
graph, to find differences between IEC

and UL test protocols.
The end result is a phase-in of a new
series of standards, UL 60947-4. UL
60947-4-1 most closely resembles UL
508. Phase-in dates vary. See article
online for details. After Jan. 27, 2017, all
products must meet UL 60947-4.
The committee worked on harmonizing the UL and IEC standards, but
there are intrinsic differences in voltages
used around the world that affect testing.
Within those parameters, the committee
worked on normalizing the standards so
manufacturers will have an easier time
testing their products against the various
iterations.
- Tom Fowler, staff product specialist, Schneider Electric. Edited by Chris
Vavra, production editor, Control Engineering, cvavra@cfemedia.com.
Industry 4.0 group

looking to expand
Platform Industrie 4.0 seeks to
broaden the understanding that
Industry 4.0 needs to be understood
as a project for society. The group
is planning to create close alliances
with associations in the public and
private sector and in the general
populous, to bring greater awareness
of what the digital economy can do
for Germany.
Industry 4.0 represents the fourth
industrial revolution with the use of
cyber-physical systems. The goal of
Industry 4.0 is to facilitate the emergence of the intelligent factory, characterized by adaptability, resource
efficiency, ergonomics, and integration of customers and business
partners in business and value processes. It was adopted in the Action
Plan for High-Tech Strategy 2020 in
November 2011 by the German federal government. Platform Industrie
4.0 aims to serve as a moderator and
catalyst for the exchange of information among groups.
- Chris Vavra is production editor, Control Engineering, cvavra@cfemedia.com.
Go Online
Learn more about Platform Industrie 4.0:

www.plattform-i40.de/
CFE Media is hosting a webcast series on
Industry 4.0 and the Industrial Internet of
Things (IIoT).
www.controleng.com/webcasts
20
See more news daily at www.controleng.com/news
Standards group on counterfeit pharmaceutical packaging

The Steering Committee of the Open
Serialization Communication Standard
Working Group (Open-SCS) announced
the accelerated development of an
industrial interoperability standard and
associated requirements templates by
year-end 2015 to focus on health care
packaging serialization interoperability
across a plants equipment and systems
and between the supply chain systems.
Since the 2012 patent cliff, generic
products now make up 80% of the global health care market and are a primary counterfeiting target where counterfeit drugs flood the market and generate
about $75 billion revenue annually;
The counterfeit industry is estimated to
grow 20% annually; Counterfeit drugs
constitute as much as 70% of total drug
supply in some countries.
McKinsey & Company said, Global standards could enable substantial
patient safety benefits and enable total
health care cost reduction of $40 to 100
billion.
In September 2014, Open-SCS
founding members first gathered in
Frankfurt, Germany, as the Open Architecture for Track & Trace Group to
address these issue. More than 80 health
care manufacturers, solution providers,
suppliers, and consulting companies
contributed to develop inter-plant serialization solutions to improve deployment efficiency and high cost of compliance to the aggressive regulations.
Interoperability standards, such as
OPC-UA, ISA-95/88/B2MML, EPCIS, PackML, and others, cover most
requirements, but there are gaps, suggested Charlie Gifford, executive director of the Open-SCS Group. A single
standard interoperability implementation will sufficiently cover the entire
requirement for health care serialization
compliance, Gifford said.
Serialization legislation from many
countries dealing with the global health
care counterfeiting crisis requires
immediate serialization and aggregation of products from the manufacturer to the patient. Production floor
and warehouse equipment and systems
should exchange information with the
manufacturers supply chains and the
patients support systems. Open-SCS
said data exchanges can: 1) Define and
simplify the base roles for each actor in
the data flow to supply chain; 2) Define

the communication protocols used for
each connection point; 3) Enable greater flexibility of the serialization architecture available to the industry; and
4) Substantially reduce integration cost
and product delays from different vendors. With input from health care pro-
viders and vendors, Open-SCS plans

to release standard and implementation
specifications by year-end 2015.
- Edited from an OPC Foundation press release by Chris Vavra, production editor, Control Engineering,
cvavra@cfemedia.com.
industry
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NEWS
HEADLINES ONLINE
See www.controleng.com/news for daily coverage including items below.
Industry events
At www.controleng.com, on the right side, click into the events box and
scroll by month to see related industry events including:
Tips for automation system integration project management, RCEP
Webcast for PDH credit: Automation system integration project management, when done right from project inception, can mean the difference
between a successful implementation that adds value and one that
doesnt. Sept. 10, archived thereafter. www.controleng.com/webcasts
Pack Expo Las Vegas, Las Vegas, Nev., Sept. 28-30
www.packexpolasvegas.com/
Emerson Global Users Exchange, Denver, Colo., Oct. 12-16
www.emersonexchange.org/americas/
ODVA Industry Conference, Annual Meeting, Frisco, Tex., Oct. 13-15
www.odva.org/
AnyLogic Conference 2015, Philadelphia, Pa., Nov. 4-5
www.anylogic.com/conference
2015 Process Control & Safety Symposium, Houston, Tex., Nov. 9-12
www.isa.org/pcs2015/
www.lasertech.com/ce
877.696.2584
Top 5 Control Engineering articles

July 27 to Aug. 2: Most visited articles included: SCADA cyber security,
Industrial priorities, Automated machine tending, Robotic trends, and SIS.
Career advice for an engineering student
Ask Control Engineering blog offers advice links to resources to help with
engineering career advice.
Declining oil and gas prices
to impact world generators market
IHS says declining generator sales into the oil
and gas industry in 2015 will burden suppliers
that will look to other industries for growth.
Power sources for

highest performance in
harsh environment.
Prevalence of IoT may leave

networks vulnerable to attacks
Internet of Things (IoT) devices are prevalent in
highly regulated industries, and the infrastructure supporting those devices is vulnerable to
security flaws, according to a recent study.
Founder of first robotics company
honored on 90th birthday
Joseph F. Engelberger, a World War II veteran,
engineer, and entrepreneur created the first
robotics company, Unimation, and turned 90
years of age on July 26.
Robotics market in North America
off to strong start in 2015
The Robotic Industries Association (RIA)
reported that $840 million worth of robots were
ordered by North American companies in firsthalf 2015, setting a new record high in sales.
The new age of disruptive innovation

The Industrial Internet of Things (IIoT) has created a lot of buzz in the manufacturing space,
along with confusion and misinformation.
PMI hits 52.7% in July; outlook positive
Growth slips as oil prices and global economic
uncertainty linger, though the overall outlook
among manufacturers is trending positive.
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CFE Medias Global System Integrator Database is an interactive

community of global end-users and system integrators hosted by
Control Engineering, Plant Engineering, and our global partners in Asia and
Europe. Through this database you will be able to connect with System Integrators by
searching their corporate profiles which highlight: industries served,
engineering specialties, product experience, geography, and other pertinent data.
Find and connect with the most suitable service provider
for your unique application.
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cover story - packaging automation
Packaging machine design

Control system flexibility, a need across all industries, means easy re-use of code from one
controller to the next, scaling from two-axis machine to a high-axis coordinated motion system with the same software, reducing hardware costs, training time, and troubleshooting.
n the packaging industry, companies need

flexibility to meet evolving demands of the
marketdifferent product looks, quantities,
and sizes. This requires a range of machine
speeds to produce different product sizes
and shapes with the same quality. It introduces
the need for automatic changeover procedures to
accommodate different packaging material or fill
product types.
Important elements in control system
flexibility include software and controlKey
ler hardware. Users should easily re-use
concepts
code from one controller to the next.
Scalability is a common need across
Machine designs can
be simplified with control
all industries to keep costs low. The
system flexibility.
same software should economically
serve a simple two-axis machine and a
Scalable software and
hardware and reusable
high-axis coordinated motion system.
code help.
Scaling along a product line of controllers reduces hardware costs, training
Compatible automation
components also ease
time, and troubleshooting efforts.
added to the system by modifying the existing chain of servos

machine design time and
already on the machine. This
maintenance.
Pre-made tools
also allows for the same control
Another need is finding pre-made
cabinet across multiple families
tools for their industry requirements. It is difficult to of machines and frees the cabinet design from the
design a system for a packaging machine with a con- needs of the machine itself.
troller thats designed for the process industry. The
There are packaging OEMs that manufacture
original equipment manufacturer (OEM) needs solu- four or five lines of packaging equipment, and
tions from providers who understand their industry, each one of those product lines have multiple
know the needs of the machine, and have software machine sizes. By using a cabinet-free servo drive
tools pre-built to accommodate those needs.
solution, they are able to standardize the control
The design of the control cabinet also is impor- cabinet across all machines. Each control cabinet
tant in flexible design. Using an integrated motor is the same size, and the components are largely
and servo drive system, with the drives mount- the same, even across the different product lines.
ed out of the cabinet and on the frame of the This reduces costs significantly because the bill of
machine, addresses this need. If an OEM wants to materials is roughly the same for all machines.
design a control system for low axis count but use
that same control cabinet for a system with dozens Less inventory
Design flexibility also reduces the need to
of axes, adding more drives to the control cabinet for additional motion axes means more cabinet maintain inventory of parts. When assembly and
space, more parts, and more time to build, along field technicians are accustomed to building and
working with the same system, assembly time is
with multiple design iterations.
With some systems, it also means adding less and errors are fewer. Familiarity also helps
unnecessary components like back-planes and field service technicians to quickly find problems
extra slots that may or may not be used, to add if they arise. ce
- Allen Tubbs is product manager, electric
flexibility to the design, but at a much higher cost.
An integrated motor and drive system allows for drives and controls, Bosch Rexroth Corp. Edited
additional servos without changing the design of by Mark T. Hoske, content manager, CFE Media,
the control cabinet. Additional servo drives can be Control Engineering, mhoske@cfemedia.com.
www.controleng.com
Having a low-cost controls

solution for a simple two-axis
machine and an economical
solution for a machine with a
high-axis coordinated motion
system that runs on the same
control software is important to
keep costs down. Cover photo
courtesy: Bosch Rexroth
Go Online
See another photo with this
article online with links to
more design tips, mechanical resonance, and Industry
4.0 advances. If reading the
digital edition, click through
the headline or search on the
headline atop
www.controleng.com.
packaging automation
Pneumatic valve technology

Select manifold valves with a compact, lightweight design and digital electronics for easy
integration into automation controls platforms and maximum value. See more online.
Key
concepts
Cost of ownership, high
speeds, easy integration, and reliability make
pneumatics attractive for
machine builders.
New pneumatic valve
designs help packaging
machine builders.
Diagnostics, pressure
control, and safety capabilities will help extend
pneumatic applications.
neumatics is widely used in many

packaging machines to drive motion
and actuate machine sequences. It is
a clean, reliable, compact, and lightweight technology that provides costeffective control and actuation to help packaging
machine designers create innovative systems
while staying competitive.
Manifold valve technology plays a central role in the performance and effectiveness
of pneumatic systems. Recent developments in
this technology have increased pneumatic flexibility, modularity, and ability to integrate with
and be controlled by the advanced communication bus architectures preferred by leading packaging machine original equipment manufacturers
(OEMs) and end users, enhancing the application
that value pneumatics technology supplies.
Pneumatics-driven packaging
applications
Go Online
More on flow control, valve
design, valve intelligence,
pressure control, safety.
Link to additional pneumatic articles in the online
version of this article,
including pneumatic energy
savings, pneumatics for pick
and place, and when to apply
pneumatic actuation.
If reading the digital
edition, click through the
headline, or search on the
headline atop
www.controleng.com.
Consider this...
When considering
new machine designs,
examine new packaging
automation technologies,
including pneumatics.
26
Pneumatics can be particularly effective for

machine motion that combines or includes highspeed, point-to-point movement of the types of
products that have the weight and size dimensions typically found in packaging machines.
This includes indexing, sorting, and pick-andplace functions. It is also used for suction cups or
noncontact transfer devices.
For example, on cartoning machines pneumatics can drive multiple functions: indexing
the infeed of blank cartons onto the process line,
driving machine components that help form the
folds then close the carton folds, and moving
glue guns or other sealing devices. In form fill
and seal machines, its common to have pneumatics-driven clamping devices and heat sealers, as
well as tension controllers on rollers discharging
the plastic film that forms the bags being sealed.
Four factors continue to make pneumatics
broadly appealing to machine builders.
1. Cost of ownership: Most pneumatics components are relatively low-cost, and systems are
relatively easy to maintain and repair without
special training or outside specialists, which can
add to operating costs.
2. High speeds: Pneumatic-driven systems
move products through machine sequences at
high speedstypical systems support motion
sequences of up to 5 m/sec (16 ft/sec), and higher-
Latest generation manifold pneumatic valves, such

as the Aventics AV03 valve, integrates intelligent
electronics and bus interfaces for easy use in packaging machine controls. Courtesy: Aventics
end cylinders support 11 m/sec (36 ft/sec); these

rates satisfy a significant percentage of throughput
rates found in many packaging machine applications, such as pick-and-place systems.
3. Easy integration: Pneumatic technology
is easy to integrate into larger machine designs,
highly modular, lightweight, and compact
enough to be installed on moving machine elements such as linear modules.
4. Reliability: Pneumatic-driven systems can
offer the kind of long-lasting reliability expected from todays automation technologies. For
example, one pneumatics suppliers valve series
has been tested to operate, without device failure,
through 140 million duty cycles.
Manifold valves: Control the flow
All pneumatics systems work on the same

basic principle: One air source provides all air
pressure needed for the different components,
and it is the valve system that controls the distribution and sequencing of the air to drive individual actuators.
When selecting a valve system, the main criteria to use are the valves flow rate, the weight
and space constraints associated with fitting it
into a machine design, and valve functionality.
See more advice in the online version. ce
- Erl Campbell is industry sector manager
food and beverage, Aventics. Edited by Mark T.
Hoske, content manager, CFE Media, Control
Engineering, mhoske@cfemedia.com.
2015
packaging automation
Servos improve packaging machines

Upgrade your next machine design with servo motors to decrease downtime, decrease
footprint, increase throughout, and two other key reasons. See more images online.
nnovations in automation are drastically changing the world of packaging. Here

are five reasons to consider using servos in
machine design:
Servo motor advances
1. Less downtime for product changare driving machine
es: Historically, packaging machines have been
design capabilities.
made with very intricate mechanical designs.
Increased reliability,
This allowed for precisely synchronized movemore throughput, smaller
ment from motion technologies incapable of such
footprint, higher torque,
less wear, and easier
precise movement. Intricate designs often came
maintenance may result.
with the burden of downtime for changing the
mechanical system to accommodate a change in
the product. With the precision of a servo system, these changes can be accomplished with
the downloading of a new recipe or cam table
when an operator touches a virtual button on a
human-machine interface (HMI). This significantly reduces downtime and alleviates the need
for services from a skilled mechanical technician
for the changeover.
2. Smaller machine footprint with higher torque: Factory floor space is expensive. A
smaller machine footprint can allow for more
machines in the same space. Servos can provide
a much higher torque-to-volume ratio than other
technologies. This can allow for automation of
processes that were previously impossible. Servos also are available in
a wide variety of sizes.
A thumb-sized servo
motor can integrate an
absolute encoder with
a resolution of 131,072
pulses per revolution.
3. More throughput with less shock to
the product: Sometimes the motion profile
is just as important as
the accuracy of the final
position. Using methods
of electronic camming,
servos can provide
very smooth accelerations and decelerations
This graphic shows how sizes of Yaskawa
with very fast moves.
servo motors have decreased as performance
This can provide more
has increased. Appearing left to right are the Yasproduction per hour
kawa Sigma-1, Sigma-2, Sigma-5, and Sigma-7.
without stressing prodCourtesy: Yaskawa America Inc.
uct being packaged. In
Key
concepts
28
some cases if a product is liquid or fragile, past

automation technologies have limited the cycle
rates or damaged the product.
4. Longer lasting machines: Just as less
shock is better for the product, it is also better for
the machine. Mechanical wear can be drastically
reduced by using servos, providing a longer life
for the machine and less costly repairs. They can
also reduce the audible noise, giving the impression of a higher quality machine and helping to
improve the production floor environment. More
efficient servo technology runs at cooler temperatures, further increasing lifetime.
5. Less downtime with better diagnostic
tools: The modern multi-axis servo system uses a
network, and this architecture provides improved
diagnostic capabilities over past solutions. This
allows for high bandwidth information from the
motor to the controller. This provides a superior method of detecting and resolving issues that
arise. A servo system provides feedback on position, velocity, torque, and alarm codes that can
represent excessive temperature, friction, and
many other conditions that may occur. Trending
and comparing these values to baseline values
can detect issues long before they cause machine
breakdown. These diagnostic tools are becoming web-based so that someone could log in and
check the machine remotely.
These machine design improvements can help
machine builders, system integrators, machine
builder customers, and final product consumers. ce
- Jerry Tyson is the southeast regional motion
engineer, and Michael Miller is the regional motion engineering manager, at Yaskawa
America Inc. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering,
mhoske@cfemedia.com.
Go Online
This storys online version provides links to more information and additional images, which help explain these
points. If reading the digital edition, click through the
headline. If reading in print, search on the headline atop
www.controleng.com.
Consider this...
Which new motion technologies can best advance your
machine capabilities?
A forklift in an auto assembly plant accidentally

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Available in a freestanding or desktop version, the IceStation TITAN
features a 24-inch (16:9) viewing window, a retractable keyboard drawer and a generously sized work surface. Built
to meet NEMA 12 standards, IceStation TITAN protects computer systems from harmful dust, dirt, and splashing
fluids. With a track record of over 29 years of experience protecting electronics, ITSENCLOSURES is the one name
you can trust. To learn more about IceStation TITAN, call 1.800.423.9911 or visit ITSENCLOSURES.com.
25
software upgrades
Software licenses, upgrades

Industrial software users should use new features and innovations without costly annual
software maintenance contracts or paying for each individual software version release.
Key
concepts
Software licensing
structures are changing.
Licensing changes
offer the ability to use
runtime version free, buy
only whats needed, or
associate the license with
certain hardware provides
flexibility.
OEM intellectual property can be protected.
Inside Process, P1, and Digital Edition have other articles on software upgrades.
oftware licensing models should be

fair and flexible, offering the ability to
update to the newest available release
and implement new features. The distribution of software tools is vital to
continued industrial growth. Also of critical importance is maintaining intellectual property (IP) and
budgets to fund software development.
If, for example, users bought an automation
design and programming software license in 2000,
they should be able to download the newest version or build off the software today and run it on
the original license. Similarly, licenses from a 2010
software release should be valid for todays version. Users should be able to take advantage of
new features and innovations without having to
subscribe to costly annual software maintenance
contracts or pay for each software release.
A useful feature is to give customers the ability to generate a free trial runtime license for seven
days without restrictions. This license may be
regenerated as often as needed, which, for exam-
Trial: Companies often provide trial licenses to allow prospective customers to test software before purchasing the full product. A unique feature in
the industry, TwinCAT 3 enables customers to generate a free trial runtime
license, which runs for 7 days without restrictions. Intellectual property is preserved: If a user bought a Beckhoff Automation TwinCAT 2 license in 2000,
the user can download the newest version or build of the software in 2015
and run it on the original license. Licenses from the 2010 release of TwinCAT
3 are valid for todays version. Licensing philosophy ensures that no production machine will be down because of a runtime licensing issue. Software
module pricing depends on the IPC performance level and on software components used. Courtesy: Beckhoff Automation
30
ple, enables engineering computers to run without a commercial license. Creating a model where
engineering tools can be freely downloadable from
the web and used without registration allows engineers to use the tools to complete projects and
encourages machine development and innovation.
Avoid licensing downtime
Production is the end goal for a controls vendor, original equipment manufacturer (OEM),
or end user, and, to this point, programming
software licensing philosophy should ensure
that no production machine will ever be down
because of a runtime licensing issue. Trial
licenses can be generated in emergency situations for permanent or temporary controller
replacement on the production line.
Runtime licensing should be flexible based on
the performance level of the industrial PC (IPC)
platform and the software components used. Cost
for software modules is based on the performance
class of the central processing unit (CPU), allowing cost effective licenses. More runtime licenses
can be added as needed, providing a simple path
for upgrade, should company needs change.
The built-in ability of a unified programming
platform to run progammable logic controller
(PLC) code without fees or licensing enables users
to take machine control and test code offline from
the production machine and perform the bulk of
testing before running a line of code on the live
machine. After testing, the necessary permanent
license can be purchased, and tested and approved
code can be implemented into the system. ce
- Daymon Thompson is TwinCAT product specialist, Beckhoff Automation. Edited by Mark T.
Hoske, content manager, CFE Media, Control
Engineering, mhoske@cfemedia.com.
Go Online
A recent poll at www.controleng.com asks about average
controller age.
To access links and information about other licensing
options, click through the headline to the online version of
this article when reading the digital edition or search on
the headline at www.controleng.com.
Consider this...
Do rigid software licensing rules restrict innovation and
creativity?
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GLOBAL SYSTEM INTEGRATOR 2016 REPORT

INTEGRATE YOUR MESSAGE TO 146,000 ENGINEERS
In December, CFE Media will publish an enhanced Global System Integrator Report.
The December Report to the 146,000 readers of Control Engineering and Plant Engineering
will now feature a Corporate Close-Up, allowing system integrators to describe their
companys unique experience and success as an engineering service provider.
Below is an example of a half-page Corporate Close-Up:
Cimation
OPERATIONS TECHNOLOGY SOLUTIONS TO SUIT YOUR

AUTOMATION, INDUSTRIAL IT, AND CYBER SECURITY NEEDS
Van Wilson, Chief Operating Officer
Houston, Texas
Telephone: (713) 452-3350
info@cimation.com
www.cimation.com
Primary Industries
Chemicals, Petrochemicals
Oil & Gas Extraction (onshore, offshore)
Oil & Gas Refining
Pipelines
Information and communication
systems
Other office locations

Denver, CO
Pittsburgh, PA
New Orleans, LA
Lafayette, LA
Calgary, AB
London, UK
Cimation is an operations consulting company

delivering secure technology solutions to the
global energy industry. With experience in process automation, industrial IT, enterprise data,
and ICS cyber security solutions and more than
200 employees in 7 global offices, we are ready
to execute efficient strategies that converge IT
and operations technology.
Armed with diverse project experience, process
knowledge, and technical expertise, we improve
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industrial technology.
In our years, Cimation has executed thousands of reliable systems integration and engineering projects for oil
and gas, refining, chemical, power, utilities, and storage businesses. We understand the processes and objectives that drive industrial operations and help companies improve safety and efficiency through holistic solutions
customized to meet their business needs.
Since opening our doors in 2009, we have grown by developing trusted partnerships with both clients and
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Visit our Corporate Profile at www.cfemedia.com/global-si-database/Cimation
To start searching the Global System

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To discuss advertising in the

Global System Integrator 2016 Report,
contact Brian Gross
BGross@CFEMedia.com
630-571-4070 x2217
plantwide Ethernet
Managing the risk of IoT

Internet of Things (IoT) is growing rapidly; more devices are going online. Security is required
to protect devices and users. Industrial network design and best practices help. See six steps
for IoT risk mitigation. Digital Edition Exclusive section has a 4-page version of this article.
he Internet of Things (IoT), or variations of the term, has saturated the

media with stories of connected vehicles, networked wearables, home
automation, and smart meters. With
such significant conversation, one would think that
this market was invented yesterday, but machineto-machine communication that typically interfaces with the physical world via networks has
been with us for a long time. The less flashy devices known as industrial control systems have been
running our electric grids, oil pipelines, and manufacturing plants for decades. Like cloud computing, which partly owes its lineage to the mainframe
timesharing concepts of the 1960s and 1970s, IoT
has been rebranded.
The market for connected devices is shifting.
Like cloud technology, IoT is massively larger in
scale than its earlier generations and is growing
fast. What makes it significant, and a little scary,
is its sheer ubiquity, touching consumers and businesses alike. Use cases are expanding from narrowly focused to broad-based and life-critical
health care and transportation applications.
To understand the risk to IoT, definitions are
needed. At its most basic level, IoT implies network connectivity, the use of embedded (or limited
computing) devices, and, typically, involves some
connection to the physical world, such as measuring temperature, blood pressure, or road vibrations.
In essence, it implies network connectivity for
everyday devices that traditionally were not considered computers; however, nearly every use of
IoT also involves some traditional computer usage.
Small, embedded devices usually report their status
and receive instruction from a traditional computer
workstation, server, laptop, or smartphone.
Its better to think of IoT as less a series of
small devices and more of an ecosystem that
requires multiple components to work correctly. The supporting components, while appearing
to be normal computing devices, still need to be
adjusted for the real-time nature of and massive
data often associated with IoT. Computer networks
need to be everywhere and optimized for the volume and velocity of the data flows. And the appropriate business logic needs to be devised for what
are largely autonomous networks.
But fundamentally, IoT is about the core components that interact with the physical world. They
typically
include
sensors to measure
things like temperature, wind speed, or
presence of an object.
And
they
often
include actuators that
initiate actions like
driving a car, turning
off power, or injecting insulin. The supporting functions are
often the place where
the actions are determined, but for some
largely autonomous
devices, some of
those decisions could
be made independently based on the input the device receives.
Six IoT risk mitigation steps
Take six actions regardless of risk or budget.

1. IoT owners should identify current IoT
implementations in place, planned, or anticipated.
This may include building management systems
for heating and air conditioning or even the mechanisms used to run elevators if theyre networked.
2. Organizations should identify any security
policies or procedures related to IoT. If none exist,
companies should document high-level controls,
such as locking the elevator machine room.
3. Within three months, organizations should
ensure that device owners have applied the risk
model and reviewed the results with management.
4. Organizations should identify mitigation
steps and related costs to achieve the desired state.
5. In the next six months, organizations should
identify IoT risks that they dont control, but that
affect the organization.
6. Organizations should also participate in industry groups to encourage development of security
standards for the devices that most affect them. ce
- Gib Sorebo is chief cyber security technologist at
Leidos Engineering. Edited by Eric R. Eissler, editor-inchief, Oil & Gas Engineering, eeissler@cfemedia.com.
IoT software interacts

with connected devices
in a cycle, akin to a
control engineering process. Courtesy: Leidos
Engineering
Key
concepts
A basic understanding
of IoT and implementing
some basic steps can put
any organization on the
right track to managing its
IoT risk.
IoT is thought of as less
a series of small devices
and more of an ecosystem.
Unlike traditional information technology components, IoT-connected
devices are often more
vulnerable.
Go Online
Online link to other articles, including: Industrial Internet
of Things needs data, clouds, and analytics.
www.controleng.com
additive manufacturing
Hybrid machines, standard CNC

As the era of additive and subtractive machine tools emerges, todays controls are
well suited to handle the challenges, says a provider of CNCs and training.
Key
concepts
Computer numerical
control (CNC) has the
industry knowledge and
power to serve hybrid
machines with additive
and subtractive machining
capabilities.
Additive manufacturing
is creating parts made
from titanium, stainless,
or disparate powdered
metals.
CNC providers have prior
experience integrating
with robotic systems.
EDITORS NOTE:
Some additive manufacturing shops have rows
of additive machines,
producing parts that
may not require additional machining prior
to use, depending on
the application. Additive machining price
competitiveness with
subtractive machining
depends on complexity,
material(s), and number
of parts in the job.
Go Online
If reading the digital edition,
click on this article, which is
linked through the headline
for more information, photos,
and related articles.
www.controleng.com/magazine
Consider this...
Combining additive and
subtractive technologies
means sending a design to
a machine and receiving a
ready-to-use titanium or
stainless steel part.
34
ith the emergence of additive

machining (use of 3D printing to create actual parts) more
than a decade ago, it quickly
became a prototyping marvel.
As design changes were made, the result could be
quickly visualized in a 3D solid part. Manufacturing also appreciated the tool, as it enabled them to
see potential process problems in the actual cutting of the part. Modifications could be made on
the fly without part functionality being compromised. Lastly, for the estimators, this tool allowed
substantially better quote prepping.
Then materials for 3D printing evolved at light
speed, and the market quickly realized this technology had production potential. Making a short
run of parts on such a machine became a reality. While 3D printing machines are 5 to 10 years
away from being everyday shop production units,
another development has seen the fusion of additive and subtractive technologies into a new generation of hybrid machines.
Seemingly incompatible technologies such as
laser metal deposition and chipcutting machines
have emerged. This is fabrication and machining at its core. Existing and standard computer
numerical control (CNC) technology has been
implemented on these machines. Whether the
parameters involve laser gases, powdered metal
deposition, inert atmosphere vacuum, or fiveaxis rotation of a milling head or rotary table, the
function of the control remains nearly identical.
With CNC technology, one control can run two
varying technologies for fabrication and chipcutting, either on a one-channel or a two-channel
unit, often in tandem with a robot head or gantry
for part articulations.
At the 2014 International Manufacturing Technology Show (IMTS), this technology was introduced when running a lathe and a robot on the
same CNC was already possible, without a secondary programmable logic controller (PLC) or
unique robot language commands. A next logical
step would be to create additive and subtractive
technologies within the same machine. Parts made
from titanium, stainless, or disparate powdered
metals are being built up, joined, machined, or otherwise processed on machines today. Driven gears,
for example, are now laser welded from machined
and stamped components into one assembly.
Figure 1: Laser metal deposition for additive

manufacturing meets conventional metal cutting,
subtractive manufacturing on the same machine,
running one CNC in an
inert atmosphere. All figures courtesy: Siemens
Industry
Figure 2: A turbine
housing made from
titanium uses the
machine and processes
described here.
The CNC, when controlling radically different machine operations, uses a modified set of
code but not a different language, as was previously necessary with robotic integration. Since
advanced CNC units carry a secondary channel,
the commands easily can be set up there, if not
incorporated into the main channel. It depends on
the complexity of the motion and total number of
parameters being controlled. Simultaneous control
and monitoring of laser metal deposition and fiveaxis milling functions present little challenge to the
high-end CNCs on the market today.
The next decade surely will be an exciting time
in the machine tool and fabrication world. Just
remember: CNC is in control. ce
- Randy Pearson, is an international business development manager, Siemens Industry Inc.,
Drives Technologies, Motion Control-Machine Tool
Business. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
In the Digital Edition Exclusive section, see a
related article about metals used in 3D printing.
digital edition
EXCLUSIVE
www.controleng.com/DigitalEdition
Control Engineering
Digital Edition benefits:
Benefits of the Control Engineering Digital Edition include tablet-friendly viewing (HTML5), exclusive content in every issue (more than 20 extra pages here);
headlines link to the longer version posted online; links are live where a URL is
provided; and an email link arrives when ready.
DE-1 Industries using metal for 3D printing
Metal use for additive manufacturing is growing rapidly, and metals are being used for customized and mass production by a variety of industries, according to a report by IDTechEx. Metals
in use or under investigation include titanium, nickel, aluminum, cobalt, and their alloys.
SOFTWARE UPGRADES
DE-3 Do you really need a specification document?
A well-written design specification that has been thoroughly reviewed and discussed can
greatly minimize startup headaches and number of design changes.
DE-7 Gateways for the Industrial Internet of Things: Trends

Industrial Internet gateways help translate among competing, closed silos of closed,
proprietary stacks. Integrated cloud services add device usefulness.
DE-13 Capitalizing on the Internet of Things: Revenue potential

Manufacturers are in the fourth industrial revolution led by the Internet of Things (IoT).
Smart objects help. See three ways to monetize IoT devices and 10 software considerations.
DE-17 Legacy software blues
Is the legacy software platform holding projects back? Virtualization can offer a safe and
affordable path forward.
PLANT-WIDE ETHERNET
DE-19 Ethernet networks add health, visibility to industry
A converged network approach and greater cross-team visibility of edge devices create
reliable, industrial networks in step with Industrial Internet of Things (IIoT) and big data.
DE-23 Acadian Seaplants: Ethernet helps with 40% capacity

increase
A new processing facility with Ethernet infrastructure allowed Acadian Seaplants to increase
capacity with flexibility, visibility, and easier maintenance.
DE-26 What kind of fieldbus is needed for Industry 4.0?
High connectivity and powerful communication capacity are necessary between equipment
and servers to realize the dream of connecting smart manufacturing with all things. Fieldbus
organizations are seeking new ways to adapt the new needs of industry.
DE-27 Managing the risk of the Internet of Things
The Internet of Things (IoT) is growing rapidly. More devices are going online. Protect devices, systems, and users with smart industrial network design and cyber security best practices.
See risk formula graphic and six steps for IoT risk mitigation. This expands on the p. 33 article.
www.controleng.com
digital edition
EXCLUSIVE
3D printing with metal

An IDTechEx report said that 3D printing with metal is growing rapidly and that
metals are used for customized and mass production by a variety of industries. Additive
manufacturing metals in use or in testing include titanium, nickel, aluminum, and cobalt.
Key
concepts
Additive manufacturing
is being used for mass
production.
3D printing in metal is
the fastest growing segment of 3D printing with
the aerospace and medical industries using it for
mass production.
Some industries, like
jewelry, are 3D printing in
metal for custom projects.
D printing encompasses a variety of

different printing processes and is primarily additive in nature. Each of the
technologies is suitable for use with
a different range of materials, which in turn
defines the suitable applications of the printer.
3D printing may have started with form and
fit testing for prototypes, but the technology
has evolved in the past few years to encompass
manufacturing products on a mass scale.
With 3D printing, designs are not constrained by manufacturing limitations, and
design complexity no longer adds cost. This
opens up design avenues and enables the economic production of lighter components. This
aspect is critical to the aerospace and automotive industries.
3D printing in metal is being used to manufacture parts in a wide variety of industries.
Metals are the fastest growing segment of 3D
printing, with printer sales growing at 48%
and material sales growing at 32%, according
to the IDTechEx report titled, 3D Printing of
Metals 2015-2025.
Adoption by high-value,
low-volume industries
Consider this...
What other industries could
rapidly scale up use 3D
printing in metal for mass
production, apart from the
aerospace and medical
industries?
DE-1
The IDTechEx report states that high-value,

low-volume industries such as aerospace and
biomedical have been the earliest adopters of
3D printing in metal because of the current
speed. For example, GE Aviation has invested
more than $3 billion to house 3D printers to
print 100,000 fuel nozzles by 2020. In addition to titanium, the aerospace industry also
is investing in cobalt, nickel, and aluminum
alloys to be used in additive manufacturing.
Arcam, which manufactures electron beam
melting (EBM), has used 3D printers to manufacture more than 50,000 orthopedic implants
for the medical industry.
The report states that both industries have
a strong need for titanium alloys and combine
for a market share of 31% by volume. In addition to titanium, the aerospace industry also
is investing in cobalt, nickel, and aluminum
alloys to be used in additive manufacturing.
3D printing in metal objects also is being
used in the dental industry. According to the
report, dental supplier Argen Digital is produc-
ing metal substructures to make copings and

bridges with the same properties as cast parts.
3D printing in metal is also used for more
creative outlets as well as mass production. The
report states that the jewelry industry is very
invested in 3D printing metal objects. Jewelers
were early adaptors of selective laser melting
(SLM) technologies, which allow the designer
to customize precious metals with relative ease.
The jewelry industry is driving 3D printing in
precious metals, with gold powder having a
49% market share by revenue.
3D printing is a natural extension for the
jewelry industry because there are no qualifying standards for jewelry; designers are already
good at computer-aided design (CAD); designers are skilled in finishing and polishing and
are accustomed to making items; and designers
crave artistic freedom and unusual designs.
3D printings profile is growing
Local Motors put 3D printing in metal in

display at IMTS 2014 in Chicago with the
demonstration of their 3D printed car. The
printing process lasted the entire show, using
carbon fiber as the material, and ended with
the car driving around at the end of the event.
Everything on the car that could be integrated
into one piece (such as the exterior and the
chassis) was printed. While it took several
days for everything to come together, the concept alone is an example of where 3D printing
is going. The technology is enduring growing
pains as users continue to work out the bugs.
IDTechs report suggest that many industries
see metal 3D printing in their future, and it
will become a mainstay in mass production
before people realize. ce
- Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.
Go Online
Learn more about 3D printing in metal from the IDTechEx
report here:
www.IDTechEx.com/3dmetals
Learn more about Local Motors 3D printed car and their
plans for the future:
https://localmotors.com/3d-printed-car/
No matter what your social networking preference is,

theres a way for you to connect with Control Engineering!
Make the connection now...
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socialMed_fillePG_ce.indd 1
10/8/2013 3:19:13 PM
digital edition
EXCLUSIVE
Do you really need a

specification document?
A well-written design specification that has been thoroughly reviewed and discussed
can greatly minimize startup headaches and number of design changes.
Key
concepts
A specification is something that tells people
what they should build.
The detailed design
specification is typically
divided into two sections,
hardware design and software design.
Making changes after
the project is configured
is sometimes necessary,
regardless of the planning, and adds time to the
project.
he most common specification for a

distributed control system (DCS) is an
I/O list written on a paper napkin.
That is an old joke, but it is truer
than someone may realize. Many initial DCS
requests for quote (RFQ) are based simply on
an approximate input/output (I/O) list and the
number of operator stations required. While
this can result in a reasonable ball park first
pass estimate, the accuracy of that first pass will
depend on how close the initial I/O count was to
the actual I/O required to complete the system.
A specification is something that tells people
what they should build. Without a specification
they dont know what to build. A well written
design specification that has been thoroughly
reviewed and discussed can greatly minimize
startup headaches and number of design changes. Think back to the paper napkin specification. It is a pretty big risk for a company to
venture into a complex project without a written
understanding of the functional requirements,
with results that could last 20 years.
There is benefit and value to a specification for complex controls projects. In the
controls world there are two basic types of
specifications: Functional design specifications
and detailed design specifications. These specifications help address two critical objectives of
a project: setting and staying on budget and setting and maintaining the schedule.
Functional design specification
A functional design specification defines the

overall design and functions that the system needs
to perform the operations required to execute
a successful project. It is typically used to help
develop a budget plan for the project or plant. It
describes how the plant or unit will operate and
allows the user to obtain budgetary bids based on
a more detailed set of criteria than just basing the
bids purely on a list of inputs and outputs.
If a specific platform has already been standardized, the initial development of a specification may be a bit easier to develop. It also
narrows the number of system integrators from
DE-3
which to choose, provided that the list is of integrators who have demonstrated experience on
the chosen platform.
If there is no specific platform selected, having a functional design specification will help
ensure that the process of selecting a platform is
based on a defined set of criteria. When people
request bids based on paper napkins, they will
get a wide range of bids. Some may provide a
Cadillac system, while others will quote an
economy car and hope to upsell later on features that are actually needed.
The functional design specification helps
identify, in writing, the product being made,
how someone should make it, the plant areas
and units, if the process is batch or continuous,
programmable logic controller (PLC) or a DCS,
remote racks or a central rack room, reporting
requirements, and if theres need for remote
viewing capabilities. In addition, the specification can help plan the actual testing methods
and conversion strategy to include downtime
requirements and critical components.
By having these and other items listed in the
specification, a team will create a solid basis to
receive reasonably similar bids from the request
for proposal (RFP) that accounts for all aspects
of the project. Two comparison examples of
customers experiences with functional specifications follow.
Two case studies
A customer recently needed to upgrade

a units control system that has been in place
since the mid-1980s. The company had been
using the equivalent of EBay for a decade to
keep the system running and several key personnel retired, taking with them a vast knowledge base that had kept the system running
for the past 30 years. Most DCS systems are
designed to be in place for 20 years, but are
rarely designed to actually run for 30 years
without major upgrades in technology.
The customer decided to purchase a frontend engineering and design (FEED) study,
which is another name for a functional design
study. This study was to help identify exactly

what was needed on the new system and to
develop a document that would allow personnel to meet vendors and obtain bids for the
replacement system. For the FEED study, four
companies spent a week on-site pouring through
the original documentation for the system and
going through the updates that had been made
on the documentation, as well as walking the
plant to assess the electrical and mechanical
requirements for the new system.
Fortunately, they had done a reasonably
good job of updating the information, but as
it was in paper form, there was no electronic
documentation that could easily be pulled into
a database. After the site visit, there was about a
2-3 week effort to produce the final FEED study
document. The document allowed the customer
to set a good budget for the project and make
a realistic assessment of downtime and implementation time required to work with production for the upgrade.
Another customer, several years back, was
building a new plant with a completely new
design. Those involved opted not to develop a
functional design specification as they wanted
to quickly get the plant up and running. By
omitting this step they suffered. Neither of the
two project objectives that were identified earlier were achieved.
They ran over budget as they were designing the system on the fly and were constantly
reworking configuration. This added cost to the
project. Because of the lack of a clear design
and the resulting tinkering, the project schedule slipped, and the personnel did not meet the
startup date. In an effort to bring the project
back on schedule, some shortcuts were taken
and, while they did help the schedule, they
caused support issues for the long term.
In the end the customer had a working system, but it was over budget and completed late.
This scenario could have easily been improved
by simply taking the time and making an investment at the beginning of the project to develop
a proper specification. The additional cost that
the company incurred was substantially more
than the cost of a design study.
Detailed design specifications
The detailed design specification is typically

divided into two sections, hardware design and
software design.
The hardware design incorporates elements
like system architecture, cabinet requirements,
cabinet distribution, cabinet design, PC requirements, fieldbus or traditional I/O devices, and
network requirements. The system architecture

determines what level of redundancy should be
used and whether a safety system is required or
a basic process control system will suffice:
n Cabinet designs should consider environmental requirements (indoor or outdoor)
and whether they may need cooling to
keep the equipment within required heat
and humidity tolerances.
n Cabinet distribution addresses if the plant
will have centralized I/O using homerun
cabling or a distributed I/O cabinet layout
in which a bus is used between areas and
shorter instrument wires are required.
Software design
also becomes a
test document
that can be used
n Cabinet design deals with how the equipment is laid out within the cabinet, as well
as power distribution, and defines typical
wiring for different types of inputs and
outputs.
during the factory
n PC requirements address the need for

standard or industrially hardened PCs.
Would a thick client architecture be
necessary in which each operator and
engineering station is a full PC with its
own locally residing licenses or a virtualized system, using thin clients at each
location?
confirm that the
acceptance
testing as a
checklist to
system performs
as intended.
Software design deals with how the process

will work. It defines how individual elements
in the process act and react. The software document will define the device and functions of
each specific device and each area of the plant.
The devices are defined as control modules
(CM). The functions are defined as equipment
modules (EM).
Developing and signing off on the software
design before beginning the software configuration provide a system integrator with a solid
basis from which to configure the system. This
should eliminate confusion on how the system
is designed to operate. The software design also
becomes a test document that can be used during the factory acceptance testing as a checklist
to confirm that the system performs as intended.
Sometimes multiple departments in the
same facility do not agree on the actual procedure the plant is currently using on a particular
application. The process of going through the
discussions to create the design specifications
forces the plant production, management, maintenance, and engineering to realize discrepancies in their understanding of plant operation
www.controleng.com
CONTROL ENGINEERING SEPTEMBER 2015 DE-4
digital edition
EXCLUSIVE
Go Online
See a Control Engineering
webcast on Tips for automation system integration project
management at
www.controleng.com/webcasts.
For more on specification
documents, read Specification documents: Pay now or
pay later at
www.controleng.com.
Consider this...
Looking back at the beginning of this article, do you
really want to start with the
paper napkin approach?
so they can discuss and agree on how to handle

particular operations.
In a current DCS system configuration scenario, a customer is building a new plant that is
an entirely new facility near an existing plant.
Working with the customer, a software design
specification (SDS) was developed. Their
engineering team had never built a plant from
scratch, which presented some issues as they
determined what new technologies to use and
what strategies to keep from the existing plant.
They decided that, even though the customer
perfected the process in the existing plant, they
did not want to simply copy it exactly without
taking advantage of new technologies. In deciding to use new technologies, there was a need
to accurately communicate to system integrator
engineers how the plant should operate.
This is a medium-sized DCS, and lot of time
was spent jointly developing the software design
specification. The software design has been a key
part of the project and has helped to reduce confusion on how specific elements of the system operate. Some initial ideas on how elements would
work have changed during the life of the project.
Making changes after the project is configured is sometimes necessary regardless of the
planning and adds time to the project. In this

case, the SDS is in place, which helped to
quickly identify what the ripple effect of the
required changes would be on the entire system, thus allowing the customer to determine
whether the changes were worth the additional
time. The SDS document acted as a test document during hardware and software checkout
and will remain as a major part of the system
documentation after the project is complete.
Avoid the paper napkin
Most control systems will be in place for

more than 20 years, and it is best not to risk a
mistake on the front end that everyone will live
with for a generation. For a nominal investment
at the beginning of a project, individual engineers and their companies can realize significant savings on the project budget and on the
lifecycle cost of the system. ce
- John Walker is an account manager
with the Cross Company, Integrated Systems
Group. Edited by Joy Chang, digital project
manager, CFE Media, Control Engineering,
jchang@cfemedia.com
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digital edition
EXCLUSIVE
Gateways for the

Industrial Internet of Things:
Emerging trends
Industrial Internet gateways help translate among competing, closed silos of
proprietary stacks that provide vertical integration between the things in the
field and the integrated cloud services that make them useful.
Key
concepts
The IIoT trend toward
fragmentation is at odds
with the needs of system
integrators and manufacturers.
Software portability
significantly improves
the development speed
and cost of connected
systems.
emote connections and new software

licensing structures can create opportunities for incremental upgrades in
control and automation software,
advancing efficiency, improving information
flow, and bringing greater optimization. The
confluence of ubiquitous, open standard-based
Internet connectivity and powerful, low-cost
embedded devices has led to the emergence of
the Internet of Things (IoT).
A projected 25-billion IoT-connected
devices are expected to be online by 2020.
This trend disrupts the established control and
instrumentation field, opening it up to a new

range of possibilities referred to as the Industrial Internet of Things (IIoT).
The development of the Internet itself has
been characterized by collaboration, interoperability, and conformance to open standards
in contrast to the foundational ethos of the
Internet. In a manner foreshadowed by proprietary mobile phone ecosystems, the IoT/
IIoT space is emerging as a new wild west in
which competing, closed silos have emerged.
Each silo is vying to lock in a maximal share
of the expected huge market by providing a
Figure 1: The FieldServer BACnet Router from Sierra Monitor Corp. is used by system integrators to
interconnect BACnet networks using different media, such as RS485 field networks and IP networks,
typically to connect the devices to a building management system. While BACnet routing is a standardized, low-level function, the FieldServer IIoT gateway architecture, on which the BACnet Router
is based, affords it the ability to host application-level functions that add value for system integrators,
removing the need for other tools to verify that all expected devices can be reached and identified.
Images and graphics courtesy: Sierra Monitor Corp.
DE-7
full, closed, proprietary stack

providing full vertical integration
between the things in the field
and the integrated cloud services
that make them useful.
The IIoT trend toward fragmentation is at odds with the
needs of system integrators and
manufacturers in control, instrumentation, building management,
and energy management fields.
Over the past two decades, these
fields have been characterized by Figure 2: The FieldServer EZ-Gateway from Sierra Monitor Corp. illustrates a standardized
industrywide collaboration in the approach to field device virtualization. In this example, a system integrator creates a profile that
creation of open standards that configures data items to be read from a Modbus device and mapped into a BACnet data model,
have exposed suppliers to more which allows the user to enrich the data model with: object name, object type, units, and descripdirect competition, while at the tion fields. Each profile can then be used to create multiple DeviceProxy instances correspondsame time expanding their mar- ing to multiple Modbus devices in the field. The image below shows four DeviceProxy instances
ket reach. The result has created being instantiated and mapped into virtual BACnet devices.
significant benefits to the industry as a whole. The convenience,
added value, and efficiency of
this approach is under threat from
the new silos.
In reaction to this danger, a
number of vendors have formed
the Industrial Internet Consortium
(IIC, www.iiconsortium.org) to
work toward establishing a consensus around interoperability.
To this end, the IIC has published the Industrial Internet
Reference Architecture Technical
Report (IIRA), which sets out an
architectural framework intended to guide the development of
Industrial Internet Systems (IIS).
The IIRA explores architectural concerns from business, usage,
functional, and implementation Figure 3: A portable data format by which device profiles that have been manually configured
viewpoints. The implementation on a gateway can be exported and shared with users via a profile sharing website hosted by the
viewpoint discusses the technol- gateway vendor. A publicly available library of labor-saving profiles are indexed by a field device
ogy and communication schemes model can be uploaded and instantiated on compatible gateways by any system integrator.
required by the reference architecture and is of special interest
for the topic at hand.
ations, and analytics) via an access network,
The IIRA outlines a number architecture which provides for data and control flows to be
patterns that largely depend on the presence of exchanged. Figure 7-2 from the IIRA illustrates
gateway devices, such as:
this pattern.
Three-tier architecture pattern with edge,
platform, and enterprise tiers
This pattern uses a gateway to connect the
edge tier (containing field devices or edge
nodes linked by a proximity network) to the
platform tier (containing data transforms, oper-
Gateway-mediated edge connectivity

and management architecture pattern
Here an edge gateway provides the link
between a local area network (LAN) of edge
devices and a wide area network (WAN) linking
to higher level services. The edge gateway may
www.controleng.com
digital edition
EXCLUSIVE
the system against the countless different data
structures encountered in the field. Similarly,
field device functions can be wrapped and presented in a coherent manner. For example, a
gateway can render a collection of very diverse
energy meters in an abstract representation that
is consistent across an IIS, thus, insulating higher tiers of the system from often unavoidable
variations in the field.
Network management
Gateways are often ideally located to host

field network management functions, removing the need for third-party network management tools.
Network discovery, self-configuration

Figure 4: Growth in devices connected to the Internet disrupts the established control and instrumentation field, opening it up to a new range of possibilities referred to as the Industrial Internet of Things (IIoT).
itself act as the provider of local connectivity

by acting as a hub. It serves to insulate the edge
devices from the WAN and can contain some
data processing, analytics, control logic, and
application entities.
As the widespread acceptance of modern,
open-field protocol standards has reduced the
need for traditional gateways in the field, the
IIoT has created a need for a new breed of intelligent gateways that unlock the full potential
of interoperability among diverse real-world
devices and industrial Internet systems.
Data management
Industrial and building automation gateways have moved far beyond the simple message translation paradigm of the classical
definition of gateways. Gateways can now
occupy all levels of the open systems interconnection (OSI) networking model. By supporting application layer entities, modern gateways
can actively read, write, and manipulate data,
as well as implement intelligent data caching, data logging, and controller functions.
Store-and-forward techniques allow for the
maintenance of continuous historical records
where Internet connectivity is unreliable or
intermittent.
Virtualization, abstraction
Beyond caching and mirroring data, gateways are becoming important providers of data
abstraction. By modeling diverse field devices
in consistent, self-documenting, virtual-device
models, gateways insulate the higher tiers of
DE-9
Taking the network management concern a

step further, IIoT gateways are becoming capable of zero-configuration deployment. Once
such a gateway has been installed in a field network, it is able to detect field devices autonomously and consolidate data and functions into
an integral interface.
Crowdsourcing
The enormous fragmentation and diversity of the existing, installed base of products
can make some degree of human interaction
unavoidable. Many legacy field protocols have
no means of describing the data they present,
forcing vendors to supply separate documentation of the data maps for each device model.
These in turn need to be manually translated
into gateway configurations for the data to
become presentable in a more integral virtualdevice model.
In a new development, a gateway vendor has
created a portable data format by which device
profiles that have been manually configured
on a gateway can be exported and shared with
the broader user community via a profile sharing website hosted by the gateway vendor. This
is giving rise to a growing, publicly available
library of labor-saving profiles that are indexed
by a field device model and can be uploaded
and instantiated on compatible gateways by any
system integrator.
Application hosting
Multi-tier architectures often require a range

of functions to be available to local operators
even while the site is disconnected from the
Internet, or perhaps in instances where a given
deployment remains isolated. Additionally,
a robust system design might require certain
monitoring and control functions to be located
locally to maintain uninterrupted operations
where Internet connectivity is intermittent.
Figure 5: Industrial Internet Consortium (IIC) published the Industrial Internet Reference Architecture Technical Report, intended
to guide the development of Industrial Internet Systems (IIS). This IIRA Figure 7-2 from the report shows a three-tier architecture
pattern with edge, platform, and enterprise tiers. The pattern uses a gateway to connect the edge tier (containing field devices
or edge nodes linked by a proximity network) to the platform tier (containing data transforms, operations, and analytics) via an
access network, which provides for data and control flows to be exchanged.
Remote access
Gateways are able to host remote access

servers, providing secure tunneling access to
remote users of applications hosted on the gateway. This minimizes the functionality required
of the cloud infrastructure and extends the
usability of locally hosted applications.
Gateway architecture developments
The expanded scope of gateway functionality places enormous demands on the productivity and flexibility of the supporting technologies.
Where gateways might traditionally have succeeded as monolithic embedded applications
programmed in C or C++, the functional diversity and flexibility required today necessitate
platforms that allow the desired combination of
services to be assembled from a range of custom, purpose-built components and third-party,
proprietary, or open-source components. The
growing convergence between traditional server environments and embedded environments is
creating important opportunities to expand the
capabilities of gateways.
Portable software platforms
Software portability significantly improves

the development speed and cost of connected
systems by enabling communications or application code to be reused on multiple platforms.
Two factors have emerged that have enabled
code sharing between edge and cloud platforms:

compatible virtual machines (VMs) and portable operating systems.
Compatible virtual machines
For the past two decades Java has made

code portable by providing compatible VM
implementations for platforms of various sizes.
While making comparatively heavy performance demands, todays edge devices are well
able to run full-featured Java VMs and can draw
on an enormous code base. Scripting languages,
such as Perl, Python, PHP, and more recently,
JavaScript, lend themselves to portable implementations because only the interpreter needs
to be ported to any new platform. JavaScript is
already the worlds most popular programming
language, and the rapidly developing Node.
js ecosystem offers a very promising portable
platform that allows code to be shared between
embedded devices, servers, and web browsers. The asynchronous, event-driven nature of
JavaScript code makes it well suited to developing I/O-intensive, transaction-driven systems. In
addition, npm, an open source package management system (npmjs.com), is delivering unprecedented growth in the number and scope of
small, focused, and high-quality modules supporting a vast range of popular protocols, services, application programming interface (API)
clients, and database clients and servers.
www.controleng.com
digital edition
EXCLUSIVE
Table: Modbus data map

Data address
Data value
(available via Modbus)
Description
(not available via Modbus)
30000
65
Inside temperature in
Fahrenheit
30001
59
Outside temperature in
Fahrenheit
80
Humidity in % relative
humidity
<more values>
31000 <last value>
31001
<a new value can be

added here, at the end>
Portable operating systems
Intruding on the historical preserve of proprietary embedded multitasking operating systems, Linux has emerged as a popular option
for embedded devices. Through the RT-Preempt
patch, the Linux kernel supports soft, real-time
systems and is typically sufficient for field protocols with millisecond-scale timing requirements. Historically, edge devices have used
custom, lightweight Linux distributions that
were often different from desktop or server
counterparts.
Canonicals Ubuntu is a coherent Linux
offering covering IIoT operating system needs
from edge to cloud through the addition of
Snappy Ubuntu Core. Snappy provides a robust,
secure, and modular update and a rollback
mechanism for embedded devices and clouddeployed servers alike.
Interoperable, composable
software modules
Go Online
More information and images on this topic are in the
online version. If reading the
digital edition, click through
the headline; if reading print
version, search the headline
at www.controleng.com.
Consider this...
As IIoT/IoT develops, many
companies are going to try
to grab as many dollars as
they can by making proprietary software, resembling
prior technology wars,
such as Betamax vs. VHS
and Blu-ray vs. HD DVD.
DE-11
Apart from the use of portable operating

systems and virtual machines, architectural
flexibility is enhanced by software design
practices that encapsulate functional modules
in interoperable and composable ways. This
generates more options for system designers to
decide whether to locate application, monitoring, or control code on an edge gateway or in
the cloud, and it maximizes efficiencies through
code reuse. In addition to offering internal and
downstream abstractions, differences between
various upstream cloud-tier providers can be
abstracted and wrapped in standard component
interfaces, enabling a given gateway implementation to be integrated into a variety of systems
with minimal effort.
Rich, self-describing data models
Beginning with XML, and increasingly

through the more compact and browser-friendly
JSON, gateways can present data and APIs in
formats that make sense by themselves, that are
inherently extensible, and that can be integrated

and interpreted by many systems.
For example, a traditional Modbus data map
would contain large number, 16-bit data registers that are identified by numerical addresses.
Such a map would typically be hard-coded into
a device, and the only possibility of extending
the map would be through appending new values at the end of the map. (See Modbus data
map table)
All this information can be expressed in one
JSON object, which can be extended without
breaking compatibility with existing implementations by simply adding fields, as shown by the
highlighted added field, Setpoint, which could
simply be inserted without affecting the integrity of the communications. The object is transmitted as a text string and is intelligible on its
own. While there is a price to be paid in that the
JSON format is much more verbose than Modbus, the advantages greatly outweigh the costs
in most cases.
JSON Data Object
{
Inside Temperature:{
Units:Fahrenheit,
Value:65,
Setpoint:63
},
Outside Temperature:{
Units:Fahrenheit,
Value:59
},
Humidity:{
Units:%RH,
Value:80
}
}
Consolidation, maturation
The IIoT ecosystem is at an early stage, and

a lot of consolidation and maturation lie ahead.
The emerging breed of IIoT gateways will contribute toward containing uncertainty and preserving the value of existing investments by
providing rapidly adaptable capabilities for keeping up with a changing environment. In their new
guise, as envisaged by the industrial Internet
architectures set out in the IIRA, IIoT gateways
will remain an indispensable part of the industrial Internet for the foreseeable future. ce
- Varun Nagaraj is the CEO of Sierra Monitor Corp. Jens Eggers is a software engineer
at Sierra Monitor Corp. Edited by Eric R.
Eissler, editor-in-chief, Oil & Gas Engineering,
eeissler@cfemedia.com.
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digital edition
EXCLUSIVE
Capitalizing on the
Industrial Internet of Things:
Revenue potential
Hardware manufacturers are in the midst of the fourth industrial revolution led by the
Internet of Things (IoT). To keep up with new technological advances, they must move
towards smart objects. See three ways to monetize Internet-connected devices and
10 software-centric business considerations.
Key
concepts
Hardware manufacturers must consider using
licensing and entitlement
management.
A connected product
with such as system
would make it easy for the
device manufacturer to
generate new revenue.
Software lets manufacturers personalize offerings without manufacturing multiple models.
DE-13
o profit from a software business

model transformation, device makers must have the systems in place to
monetize the full potential of software
investments and protect those investments in
intellectual property. Hardware manufacturers
must rethink their traditional business models
and consider the role that licensing and entitlement management play in maximizing revenue
potential. What would a software-centric business model look like?
Connected systems,
software-centric approach
Taking a software-centric approach means

manufacturers must re-design products from
fixed-function, disconnected devices to flexible,
seamlessly connected systems. A software-centric approach streamlines all aspects of the supply chain, from manufacturing to monetization.
For instance, lets say a telecommunications
company has developed a connected commercial video surveillance camera with 10 features.
Using the software-licensing-driven model, the
telecommunications company need only manufacture one physical model. Using software and
the power of licensing, the device maker then
simply turns on features one through three to
sell as the basic model. It could then turn on
features one through six and sell that model as
the premium model or turn on remaining features and sell it as the platinum model. Three
models which previously required three manufacturing supply chains are now reduced to one.
Moreover, this software-centric model adds
flexibility and nimbleness making it easy for
manufacturers to quickly configure products to
take advantage of emerging market trends, without having to alter their physical supply chain.
For instance, if software features one, four, five,

and nine are popular with Chinese customers,
a quick licensing reconfiguration results in a
model optimized for the Chinese market.
A connected product with a back-end, entitlement-management system also would make
it easy for the device manufacturer to generate new revenue streams for the camera. For
instance, the user of the basic camera could
sign on to the devices portal and purchase a
30-day trial for the premium model. Once
the credit card data is provided, the system
will unlock the premium features in the camera
and without so much as a delay, the user has
an upgraded device, and the manufacturer has
generated a new revenue stream from the additional purchase. Depending on how the trial was
set up, at the end of 30 days, the full upgrade
charge may be debited, and the camera is fully
upgraded. Or, through the entitlement-management system, the camera would automatically
revert back to the basic model.
Software-centric, with security
The same principles apply to IoT manufacturers across the spectrum of industry. Markets
as varied as building automation, telecommunications, and gaming could benefit from adopting a software-centric business model, as could
oil and gas equipment makers, test and measurement device manufacturers, and medical
equipment manufacturers.
Although building and creating these devices
is a major part of the device manufacturers job,
installing the software to allow these devices to
connect and perform is crucial. The important
thing when designing a connected device is to
install security measures from the start. In this
sense, manufacturers must ensure that applica-
Connected systems and a software-centric approach

will benefit manufacturers. Courtesy: Flexera Software
Software allows for flexible product

configurations, manufacturers can
quickly, easily, and inexpensively
package and price devices to
uniquely address new, emerging,
or niche markets.
tions use tamper-resistant licensing codes to

help reduce hacks. Companies need to invest
the time to reverse-engineer embedded software
on the device and make changes at the machine
level if necessary to strengthen protection.
This type of embedded licensing model has
been successfully used in many devices: mobile
phones with unlockable GPS functionality, routers sold in tiers based on number of supported
ports, and cameras with different signal-processing algorithms based on available licenses.
Three ways to monetize Internetconnected devices
Using automated licensing and entitlementmanagement systems to monetize Internet-connected devices offers many benefits, including:
1. Reduced manufacturing and distribution costs: Internet-connected devices controlled by embedded software significantly
reduce manufacturing costs. Companies reduce
the number of models they must manufacture
by controlling features, capacity, configurations, and throughput via software, licensing,
and entitlement management, allowing them to
build once and package functionality multiple
formats. Configuration of the products can be
postponed until the exact requirements of the
customer are determined. This manufacturing
flexibility means that producers, distributors,
and resellers require fewer inventories, greatly
streamlining the supply chain.
2. New markets and revenue streams:

IoT enables the creation of entirely new revenue streams as well as opportunities to grow
the customer base. Using a software-licensing
model for instance, manufacturers can easily
offer product enhancements through software
updates and charge for the enhanced functionality based on a software maintenance and update
model. There are opportunities to charge for
new levels of software support while simultaneously delivering a better customer experience. And because software allows for flexible
product configurations, manufacturers can
quickly, easily, and inexpensively package and
price devices to uniquely address new, emerging, or niche markets that would previously
have been impractical or prohibitive due to
costs. The additional data generated by intelligent, connected devices also can be turned into
intelligence and used to identify new potential
markets and opportunities.
3. Product life extension: Licensing and
entitlement management extends the life of
the manufactured device. Much of the functionality of devices is managed and controlled
using software, instead of being hard-coded
into the devices physical components. As a
result, product upgrades and enhancements
can be delivered using software commands
communicated to the device over the Internet. This enables the customer to derive more
value from the device over a longer period of
www.controleng.com
digital edition
EXCLUSIVE
Licensing and
entitlement
management
software helps
manufacturers
create connected
devices that
unlock new
revenue streams,
protect intellectual
property, and
implement
configure-to-order
manufacturing.
time with minimal disruption. Its good for the

manufacturer too because it offers more up-sell
opportunities for new functionality at minimal
expense and effort.
4. Understand the difference between delivering hardware and digital goodsthe

distribution mechanisms should be coordinated, but can be unique.
Licensing is the enabler
5. Understand the software value lifecycleas opposed to a one-off hardware

transaction; it is an ongoing process and
is increasingly subscription-based.
Licensing and entitlement management

software is the enabling technology that helps
intelligent device manufacturers to make their
products Internet-readyand personalize offerings without having to manufacture multiple
models.
Simple changes to the software in the
device enables manufacturers to customize the
product based on customer needs by managing
how it behavesfor example, by activating or
deactivating features, setting device capacity,
and otherwise controlling the behavior of the
product. This greatly simplifies product lifecycle management and facilitates supply chain
management.
Big data provides more insight
The usage data provided by the softwarecontrolled device also can offer insight into
how customers are using hardware, what software they use most often, and new services that
could potentially be created. Furthermore, product usage information enables manufacturers to
make conscious choices pertaining to trade-offs
between cost and value of service when packaging products and services for customers and
markets.
10 software-centric business
considerations
There are 10 key points intelligent device

manufacturers should consider when making the
leap to a software-centric model. Device manufacturers should:
1. Secure business buy-in for the transformationthis is broader than just
engineering or product management and
requires coordination across business
groups.
2. Understand the traditional software
licensing methodology and its proven
approaches that can be leveraged in the
intelligent device context.
3. Determine the appropriate software
license compliance policies and enforcement mechanisms among a wide spectrum of available options, anticipating
the flexibility needed to make changes
later as business conditions change.
DE-15
6. Create business processes to support the

value cycle of the software.
7. Implement a customer self-service
portalit can reduce operational costs
and increase customer acceptance of
software.
8. Define and execute a product management and go-to-market strategy.
9. Implement sales training and compensation policiesselling is not about selling
numbers of hardware pieces, but about
selling value.
10. Continuously fine-tune strategies for
product development, delivery, and execution to optimize revenue and margins.
By using licensing and entitlement management, manufacturers create connected devices
that unlock new revenue streams, protect intellectual property, and implement configure-toorder manufacturingdramatically reducing
inventory while facilitating greater responsiveness to changing market conditions. ce
- Steven Schmidt is the vice president of corporate development at Flexera Software. Edited
by Eric R. Eissler, editor-in-chief, Oil & Gas
Engineering, eeissler@cfemedia.com.
Go Online
See links to other IoT articles with this article posted
online. If reading the digital edition, click through the headline or search on the headline at www.controleng.com.
Consider this...
By applying pay-to-unlock-features to physical objects,
manufacturers can streamline production, increase margin levels, and quickly add revenue with the swipe of the
users credit card.
Turning research into insights

makes for better business decisions
On a quarterly basis, Control Engineering conducts

research studies on the industries and topics
covered by the publication
Studies include:
System Integration
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Process Control
Information Control
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digital edition
EXCLUSIVE
Legacy software blues

Is the legacy software platform holding projects back? Virtualization
can offer a safe and affordable path forward.
Key
concepts
When software upgrades
have gone too long, maintenance, downtime, and
other risks can increase.
Virtualization may provide a temporary fix and
flexibility while budget and
support are gathered for a
full upgrade.
hen system integrators do a really

good job, they sometimes give clients a false sense of permanence.
The delivered system may perform
so well theres never a need to think about it,
much less consider upgrading. Why consider an
upgrade when the current system works, operators
are familiar with it, and its paid for?
But as the years add up, important dates come
and go. First, the software makers window of
support closes. Support for the operating system
(OS) is the next thing to expire. Before long, the
client is counting on obsolete software running on
an aging server to keep the plant going. Theres a
time bomb sitting on the server rack, and its not a
matter of if it will go off, its when.
Due for an upgrade, uncommitted
This was the scenario presented recently by a

long-time customer. Many years ago, two redundant human-machine interface (HMI) servers had
been installed. Both were running RSView32 from
Rockwell Automation on Microsoft
Installing two host servers would
Windows
Server
maintain the failover redundancy,
2000 (SP2), and the
give plenty of room to virtualize other cracks were starting
to show. HMI climachines over time, and provide a
ents were freezing
platform for a new HMI system.
up mysteriously, and
the customer could
see its venerable system was on its last legs.
The servers were due for an upgrade, but the
customer wasnt ready to commit. That scope of
work wasnt in the budget, and the client needed an immediate fix. The challenge was to craft
a solution that would meet immediate needs and
position the system for future upgrades.
Virtualization provided the client with flexibility for future development while allowing
Go Online
virtual machine copies of the existing servers
At www.controleng.com/blogs,
to safely remain on the network. Installing two
read more about system integration from Maverick Technologies host servers would maintain the failover redundancy, give plenty of room to virtualize other
blog, Real World Engineering
machines over time, and provide a platform for
Creative teamwork
a new HMI system.
Safety instrumented systems:
The plan was to deliver freshly installed
Tips from the trenches
Timekeeping protocols for con- virtual instances of the Microsoft Server 2000
trol systems: What time is it?
machines on the new host servers, but make
DE-17
clones of the originals to have for reference offsite. Ideally, these clones would be taken without interrupting production at the plant through
a process called hot-cloning, but the OS didnt
make that process easy.
Microsoft Server 2000 was the last server
OS Microsoft released before adding Volume
Shadow Copy Service (VSS), which is what
most physical-to-virtual (P2V) conversion software packages use to make clones.
One of the most popular packages is VMWare
vCenter Converter, and its most current version is 6.0. The last version to support Microsoft Server 2000 was VMWare Converter 3.0.3
Build 89816, which cant be downloaded directly because that version is no longer supported.
Thankfully, a quick Google search helped.
Converter 3.0.3 has two versions. The hotclone version requires an installation on the
machine that should be cloned. The cold-clone
version is a bootable disc that will allow cloning without a software footprint, but its necessary to take the server out of production to
make the clone. With either version, a simple
wizard guides the process and gathers relevant
parameters like destination and machine name.
When considering cloning to an external
USB drive, remember there is a limit on the
size of the discs recognized by Microsoft Server
2000 that varies depending on the Service Pack
level in use. When the cloning process is done,
the result will be a .VMDK file with a (hopefully) working copy of the cloned machine.
The process described is specifically for a
Server 2000 machine. When cloning anything
with a newer OS, find the most up-to-date conversion tool that will support it. Newer versions
yield better results.
Timely upgrades are always best, but virtualization can help squeeze that last bit of life
from legacy software while laying the groundwork for system upgrades. Its a powerful tool
that provides many valuable options, now and
for the future. ce
- Tim Gentry is an engineer at Maverick Technologies, an automation solutions provider offering
industrial automation, and a CFE Media content
partner. Edited by Chris Vavra, production editor,
Control Engineering, cvavra@cfemedia.com.
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digital edition
EXCLUSIVE
How Ethernet networks

can add health, visibility
to industrial applications
As the number of devices increase in automation networks, management and issue diagnostics become more challenging for automation and information technology (IT) professionals. A
converged network approach and greater cross-team visibility of edge devices create reliable,
industrial networks in step with Industrial Internet of Things (IIoT) and big data initiatives.
Key
concepts
Industrial Internet of
Things (IIoT) requires
Ethernet.
Ethernet visibility and
diagnostics are needed for
reliability.
Smart switches improve
reliability.
s Ethernet continues to upgrade

for industrial networks, companies
also seek to deepen the integration
between industrial automation systems and enterprise applications. What efficiencies can unfold with assembly fault data
analysis occurring in a back-end information
technology (IT) process, or what golden business intelligence can be discovered in materials
waste data linked to material vendor invoicing?
Networking flexibility opens business implications in ways upper management cannot ignore,
even in 2015.
IIoT requires Ethernet
Industrial Internet of Things (IIoT) innovations in sensor technology, wireless connectivity, energy harvesting, big data, and cloud
computing are part of the seamless exchange of
information among devices, systems, and people, paving the way for improved performance,
flexibility, and responsiveness throughout the
enterprise value chain. This points back to the
Ethernet; the industrial Ethernet network needs
to deliver the data so big data analytics can
deliver results.
Considering the Ethernet requirement for
more high-speed processes, as well as more
data gathering, factories will need a redundant
network; one that easily resolves network issues
in the control layer. Radiating out, full network
visibility would be implemented to ensure a
dependable network to edge devices.
Fortunately, a host of available layer 3 router
and layer 2 managed switches can provide core
network needs. What about layer 2 unmanaged
(edge) switch requirements that must stretch
to incorporate such characteristics as port status visibility at the IP address level and employ
port quality of service (QoS) to ensure a work-
DE-19
ing model for the enterprise needs as much as

the automation network? This is a switchs role
usually reserved for robust, managed switches,
but the drawback is that such switches deployed
on the edge can be costly and require a lengthy
ramp-up time to implement.
Lower-cost managed switches
On this topic, IHSs John Morse predicted

that the introduction of lower cost, lower functionality layer 2 switches will economically
serve the need of users as networks are expanded to meet the degree of connectivity required
to join the industrial IoT revolution. Also in a
2014 report on the market for industrial Ethernet infrastructure components, IHS said: This
trend may, in the longer term, see the demise of
the unmanaged switch as the prices converge,
much in the way the hub has become all but
extinct.
To allow port status visibility for automation
and IT software, the layer 2 unmanaged switch
acting as the edge switch must support Modbus/
TCP and simple network management protocol
(SNMP) communications. This allows supervisory control and data acquisition (SCADA),
human-machine interface (HMI) software, and
IT network management system (NMS) software to monitor the switch device status in real
time.
Ethernet reliability
As more programmable logic controllers

(PLCs), input/output (I/O) devices, terminal
computers, and HMI become more Ethernetconnected, Ethernet will increasingly require
the always-available adjective. It becomes an
exponential resource drain for automation teams
that continue without an update that provides
visibility to the networks edge. As edge devic-
Supervisory
control and
data acquisition
(SCADA), humanmachine interface
(HMI) software,
and IT network
management
system (NMS)
software can
monitor Ethernet
switch device
status in real
time.
Figure 1: The industrial Ethernet network built to handle big data initiatives will provide device layer
visibility for the central IT layer. Advantech ProView switches enable convergence management to
meet IIoT and big data scale network upgrades. The ProView switch series supports Modbus/TCP
and SNMP protocols, allowing SCADA/HMI software and IT NMS software to monitor the switch
device status in real time. Figures courtesy: Advantech
As more
programmable
logic controllers
(PLCs), input/
output (I/O)
devices, terminal
computers, and
HMI become
more Ethernetconnected,
Ethernet will need
to be always
available.
Figure 2: A network diagnosis model supports real-time, port-status viewing on SCADA/HMI and
NMS used by central IT. Advantech ProView series of switches allow IT to control or perform certain
configuration capabilities, such as setting device location, device IP mode, device IP, device netmask,
default gateway, and read/write community name. The switches can provide statistical information
including count on unicast, multicast, and broadcast packet for each Ethernet port. The switches support SNMP traps, which automatically notify the SNMP server during events.
www.controleng.com
digital edition
EXCLUSIVE
Temperature sensor
data might be
important for the
factory engineer for
process analysis
and for the IT
department for
cloud cold storage
and business
process analysis;
either team could
be enabled to send
or receive alerts if
data loss becomes
apparent.
Go Online
Click through the headline
in the digital edition to read
this article online for related
links, or search on the headline using the search box
atop www.controleng.com.
es multiply, and the data gathering functions

increase, the personnel needed to check buggy
switches would be less available, translating
into lost data and lost revenue if the connection
serves an automated process.
Greater network visibility expedites troubleshooting for automation and IT teams. Edge
switch technology that supports Modbus/TCP
and SNMP protocols will be the enabler for this.
In this model of converged networking,
teams can work towards resolution of network
issues fast.
Data from a factory temperature sensor
might be important for the factory engineer for
process analysis and for the IT department for
cloud cold storage and business process analysis; either team could be enabled to send or
receive alerts if data loss becomes apparent.
Enabling diagnostics
However, the next step is more powerful:

Either team can diagnose that there is a disconnected Ethernet line to port 5 of the edge
switch I/O input hosting the temperature sensor
and inform on the necessary fix. This is made
possible with an edge switch that has onboard
agents for Modbus/TCP and SNMP protocols.
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and automation.
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The more intelligent edge switch provides

detailed statistical information on each port
including speed, linkup counter, count on the
multicast packet, count on unicast packet, and
count on error. With the edge switch also supporting SNMP it will allow the IT teams network management system or station software
to perform status monitoring in tandem. The
fix is employed and data restored at the speed
of todays more business-minded automation
networks.
Ethernet network transformations like
these will take place to keep up with the growing number of devices and the variety of data
demands. An Ethernet network can be easily
viewable from the device layer to control layer
to the central office. ce
- Ken Kao is product manager for Advantechs industrial networking team. Edited by
Mark T. Hoske, content manager, CFE Media,
Control Engineering, mhoske@cfemedia.com.
Consider this...
Perhaps smarter switches can add to your Ethernet network intelligence.
stay
informed
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digital edition
EXCLUSIVE
Acadian Seaplants:
Ethernet connections help
with 40% capacity increase
New seaweed-processing facility with Ethernet infrastructure and integrated motor
control centers allowed Acadian Seaplants to increase capacity by 40% and provide
flexibility, visibility, and improve maintenance without production disruption.
Key
concepts
Hard-wired networking
discourages upgrades and
optimization.
Ethernet facilitates easier expansion, changes.
Easier maintenance, less
downtime, and increased
visibility are among other
Ethernet benefits.
seaweed producer switched from

hardwired controls to use of Ethernet to facilitate a 40% increase
in production without downtime,
while improving maintenance via remote support, increasing visibility, and providing flexibility to make production changes as needed at
a lower cost.
Seaweeds natural nutritional and healing
powers have been known for millennia: The
Romans applied marine plants to help heal
wounds and rashes, and the Japanese made it
a dietary staple. Today, processed seaweed
is a key ingredient in everything from human
Before and during expansion into the Dr. James S. Craigie Research Center in Cornwallis, Nova Scotia, Canada, Acadian Seaplants found that the
TechConnectSM service from Rockwell Automation, with 24/7 phone support, helped the engineering team solve issues quickly, especially in the early
stages of plant automation. The engineering team installed three EtherNet/
IP-enabled CompactLogix PACs to manage system functions. The team easily set up and configured the MCCs using the same software as the PACs,
Rockwell Software Studio 5000 Automation Engineering and Design Environment. IntelliCenter software that monitors the MCC also can send the motor
control device information directly to Studio 5000 software. Images courtesy:
Rockwell Automation
DE-23
nutritional supplements to animal feed. Acadian

Seaplants, based in Dartmouth, Nova Scotia,
Canada, cultivates and processes seaweed for a
variety of products in this international industry. One of those products is crop biostimulants,
derived from a species of seaweed called Ascophyllum nodosum, used to improve the health
and growth of plants.
Hardwired inflexibility
Acadian Seaplants produces crop biostimulants in liquid and powder formats at its facility
in Cornwallis, Nova Scotia, Canada, and ships
branded products to more than 80 countries. Its
proprietary production process starts with locally
and sustainably harvested seaweed. Then various
bio-active compounds are extracted, clarified, filtered, and concentrated. Finally, the compounds
are tested for quality, preserved, and packaged.
This complex manufacturing process requires
a high degree of process control. Before 2006,
motor controls and facility communications were
hardwired. If the company wanted to change or
add a step in the production process, rewiring
areas in the facility would be required.
Between 2006 and 2008, the company began
automating the Cornwallis facility. Modernization wasnt enough to meet growing demand.
In the last decade, the use of natural biostimulants in agriculture and horticulture increased
substantially, and Acadian Seaplants needed to
grow and upgrade its biostimulant production
facility in response. The company decided to
build onto its existing plant to add capacity and
automate the new equipment to increase process
control and manufacturing efficiency.
Easier integration with Ethernet
Electrical supplier, Graybar, knew Acadian

Seaplants was already using Ethernet-enabled
programmable automation controllers (PACs)
from Rockwell Automation. To help Acadian

Seaplants expand without adding hardwiring for
motor controls, Graybar proposed using motor
control centers (MCCs) also enabled by EtherNet/IP (an Ethernet protocol from ODVA), so
the MCCs could easily integrate with controllers in the existing system.
Acadian Seaplants continued to automate
existing processes and increased production
capacity by about 50% between 2008 and 2009.
But by 2011, the company needed to expand
again and decided to build a much larger plant
across the street.
The proven technology in the existing space
needed to be implemented on a larger scale.
Downtime during expansion would have made
it difficult to continue to meet orders. In the
new facility, Acadian Seaplants also wanted
to expand its recently implemented integrated
MCCs and controllers and enable remote support to reduce maintenance time.
Three-year expansion
Over three years, the Acadian Seaplants

engineering team moved existing processes
and equipment into a new facility, the Deveau
Center. The plant science division gained three
times more manufacturing space, meaning they
needed more equipment. Experiences from the
2009 expansion were applied to help Acadian
Seaplants implement a similar MCC implementation at a facility five times the size of the
original operation.
With counsel from Graybar, the Acadian
Seaplants engineering team designed an integrated plantwide infrastructure for system monitoring and motor control over EtherNet/IP.
The network became critical when the
Acadian Seaplants team worked in stages to
move existing processes to the new site. To
start, the team built a piping system over land
and under the street to move liquid product between the two facilities. As the team
installed new equipment, they connected it
via EtherNet/IP to the existing equipment on
the other side of the street.
Acadian Seaplants subscribed to remote
maintenance services for many years, providing
24/7 phone support to help the engineering team
resolve issues quickly, especially in the early
stages of plant automation.
The engineering team installed three PACs to
manage system functions. The PACs seamlessly
connected with other system components via an
EtherNet/IP network. System information was
fed to a desktop computer on-site, where staff
could monitor operations in real time.
Centerline MCCs from Rockwell Automation provide precise motor control

and power. Electrical supplier, Graybar, knew Acadian Seaplants was already
using Allen-Bradley CompactLogix PACs from Rockwell Automation. To help
Acadian Seaplants expand without adding hardwiring for motor controls,
Graybar proposed using Allen-Bradley Centerline MCCs with IntelliCenter
technology.
The Acadian Seaplants

team moved the existing MCCs and installed
additional ones to provide
precise motor control and
power in the seaweed-processing facility.
The team easily set
up and configured the
MCCs using the same
engineering and design
programming
software
environment.
Related
software that monitors
the MCC also could send
the motor control device Bulletin 1606-XLP Compact Switched Mode
information directly to Power Supplies from Rockwell Automation
the design and program- are EtherNet/IP-enabled. The Rockwell Softming software, which ware Studio 5000 software recognizes the
recognized the intelligent intelligent components in the MCCs, including
components in the MCCs, variable speed drives and full-voltage startincluding variable speed ers. The add-on profiles immediately provide
drives and full-voltage parameters for each component for faster
starters. Libraries of soft- configuration.
ware objects (blocks of
code) immediately provided parameters for
each component for faster configuration.
No downtime, demand met
The new seaweed-processing facility was

completed in 2014 without downtime, and Acadian Seaplants gained the production capacity
necessary to meet immediate crop biostimulant
demand. Already, the facility is operating at
40% higher capacity than the previous facility.
www.controleng.com
digital edition
EXCLUSIVE
With its EtherNet/IP-based design, the facility

could grow to 250% the prior output.
The facility isnt static. Acadian Seaplants
may need to change functions one day, do
improvements the next, or add processes. With
the controls connected via EtherNet/IP, wires
are virtual, and the company can make changes a
With the Ethernet connections,
lot faster at a lower cost.
in case of any issues,

engineers can gain remote
access securely, helping to
immediately reduce downtime
compared to previously
required on-site visits.
Improved access
With integrated MCCs

and controllers, Acadian
Seaplants gained a more
connected, reliable, and
continuous facility. Information is now shared
more seamlessly between
processes and operators. In case of any issues,
engineers can remotely access the desktop computer, helping to immediately reduce downtime
compared to previously required on-site visits. Issues automatically appear on the operator screen, a human-machine interface (HMI),
making them more visible to operators than the
previous mechanical blinking lights.
Based on the success of Acadian Seaplants

expansion, the company is considering similar
changes at other facilities. The engineering team
has begun to automate processes with PACs at
the food science divisions land-based cultivation
facility and would like to move to EtherNet/IPenabled MCCs at the animal science divisions
facilities in the next few years. ce
- Wade Hazel is engineering manager for
Acadian Seaplants. Edited by Mark T. Hoske,
content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Go Online
If reading the digital edition, click through the headline to
reach article links with more photos and links to related
information on Ethernet protocols, Ethernet use in process
control, and EtherNet/IP implementation tips. Or search on
the headline atop www.controleng.com.
www.acadianseaplants.com
Consider this...
When doing a cost-benefit analysis of an upgrade that
includes Ethernet, are lost opportunity costs part of the
calculation?
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EXCLUSIVE
digital edition
What kind of fieldbus

is needed for Industry 4.0?
High connectivity and powerful communication capacity are necessary between equipment
and servers to realize the dream of connecting smart manufacturing with all things. Fieldbus organizations are seeking new ways to adapt the new needs of industry.
egardless of Industry 4.0

in the era of Industry 4.0 and IoT.
or the Industrial Internet
ETG and OPC aim to apply proof Things (IIoT), high
tocol to the real-time communiconnectivity and powercation between controllers at the
ful communication capacity are
equipment layer and slave stanecessary between equipment and
tions; use the Extensible Authenservers to realize the manufacturtication Protocol (EAP) for the
ing worlds dream of connecting
communication between horismart factories with all things.
zontal controllers and controllers
High-speed, efficient, and safe
in the field; and apply OPC UA
fieldbus provides the basic guarto the vertical communication to
antee to smart factories.
Martin Rostan is execu- connect non-EtherCAT systems to
Traditional Ethernet has three tive director of EtherCAT meet all communications required
problems in real-time communi- Technology Group
for the vertical and horizontal
cation, including low utilization (ETG). Courtesy: Conintegration of Industry 4.0.
of broadband, stacking, and lag of trol Engineering China
Future of a fieldbus
exchanger, said Martin Rostan,
organization
executive director of EtherCAT
As a nonprofit organization, ETG does not
Technology Group (ETG).
Right now, the fastest industrial Ether- collect membership fees from its members,
net technology can take only 30 s to update and members also are provided free access to
1,000 input/output (I/O) devices; one Ethernet protocol stacking, sample codes, evaluation
frame can process 1,486 bytes of process data toolkits, and implemented support and other
exchange, at most, and communicate with 100 services at a lower price. This is the reason
servo axes per 100 s, while providing nanosec- why EtherCAT may be well accepted. From
February 2014 to February 2015, 412 members
ond synchronization.
joined the ETG. ce
Transition to Industry 4.0
If there is one ideal to summarize the hottest topic Industry 4.0, Martin Rostan believes
that it is the integration of automation and
information. For seamless connection with all
enterprise information, the data transmission
should be implemented from the equipment
and control layers to the manufacturing execution system (MES) and enterprise resources
planning (ERP) layers. The future fieldbus will
be closely connected with enterprise-level networks and even the cloud.
Based on such a vision, ETG and OPC
signed a memorandum of understanding (MOU)
at the Hanover Exhibition held in April 2015,
declaring that both organizations will develop
a common interface to better meet users needs
Key
concepts
High connectivity and
powerful communication
capacity are necessary
between equipment and
servers for Industry 4.0.
The fastest industrial
Ethernet technology can
take only 30 s to update
1,000 I/O devices.
Data transmission
should be implemented
from the equipment and
control layers to the MES
and ERP layers.
- Aileen Jin is editor-in-chief, Control Engineering China. Edited by Joy Chang, digital project manager, Control Engineering,
jchang@cfemedia.com.
Go Online
This was translated and edited for Control Engineering from
Control Engineering China.
www.cechina.cn
See other international coverage at
www.controleng.com/international.
www.ethercat.org
Online linked to:
Meeting the requirements of Industry 4.0
www.controleng.com
Consider this...
Is the fieldbus technology
you are using ready for the
Industry 4.0 transformation?
digital edition
EXCLUSIVE
Managing the risk

of the Internet of Things
Internet of Things (IoT) is growing rapidly, and more devices are going online. Protect the
devices, systems, and users with smart industrial network design and cyber security best
practices. See risk formula graphic (third page) and six steps for IoT risk mitigation.
This is a Digital Edition Exclusive full-length version of the paper-edition article on p. 33.
Key
concepts
A basic understanding
of IoT and implementing
some basic steps can put
any organization on the
right track to managing its
IoT risk.
IoT is thought of as less
a series of small devices
and more of an ecosystem.
Unlike traditional information technology components, IoT-connected
devices are often more
vulnerable.
he Internet of Things (IoT), or variations of the term, has saturated

the media with stories of connected vehicles, networked wearables,
home automation, and smart meters.
With such significant conversation, one would
think that this market was invented yesterday,
but, in fact, the machine-to-machine communication that typically interfaces with the physical world via communication networks has been
with us for a long time. The less flashy devices
known as industrial control systems have been
running our electric grids, oil pipelines, and
manufacturing plants for decades. Like cloud
computing, which partly owes its lineage to the
mainframe timesharing concepts of the 1960s
and 1970s, IoT has been rebranded.
But notwithstanding the hype, the market for
connected devices is shifting. Like cloud technology, IoT is massively larger in scale than its
earlier generations and is growing fast. What
makes it significant, and a little scary, is its
sheer ubiquity, touching consumers and businesses alike. Moreover, the use cases continue to
expand from trivial or narrowly focused applications to broad-based and life-critical solutions in
health care and transportation.
IoT defined
To understand the risk to IoT, definitions are

needed. Clearly, IoT is a somewhat fluid term
and owes its name more to media hype rather than to a multi-year standards process. Consequently, it has the know it when you see it
quality. At its most basic level, IoT implies network connectivity, the use of embedded (or limited computing) devices, and, typically, involves
some connection to the physical world, such as
measuring temperature, blood pressure, or road
vibrations. In essence, it implies network connectivity for everyday devices that traditionally were
not considered computers; however, nearly every
use of IoT also involves some traditional com-
DE-27
puter usage. For example, these small, embedded

devices usually report their status and receive
instruction from a traditional computer workstation, server, laptop, or smartphone. A typical IoT
architecture might look similar to what is shown
in Figure 1.
Its better to think of IoT as less a series of
small devices and more of an ecosystem that
requires multiple components to work correctly. The supporting components, while appearing to be normal computing devices, still need
to be adjusted for the real-time nature of and
massive data often associated with IoT. Computer networks need to be everywhere and
optimized for the volume and velocity of the
data flows. And the appropriate business logic
needs to be devised for what are largely autonomous networks.
But fundamentally, IoT is about the core components that interact with the physical world.
They typically include sensors to measure things
like temperature, wind speed, or presence of an
object. And they often include actuators that initiate actions like driving a car, turning off power,
or injecting insulin. The supporting functions are
often the place where the actions are determined,
but for some largely autonomous devices, some
of those decisions could be made independently
based on the input the device receives.
While IoT is still a relatively new concept,
core components have had populated industrial
networks for decades, and they foretell some of
the risks that could potentially be faced. Industrial networks have frequently been the subject
of cyber attacks. Unlike traditional information
technology components, they are often more vulnerable because many industrial networks were
never designed to connect to networks that were
linked to a hostile Internet. Instead, those closed
networks assumed physical attacks were the
threats to guard against.
In addition to interconnectivity challenges,
the core industrial devices, such as program-
mable logic controllers (PLCs), had

basic communication protocols that
could crash if they received any unexpected data. Moreover, PLCs were
essentially designed to process commands from whoever sent them,
sometimes with little or no authentication. That meant that if the industrial networks were not sufficiently
isolated or properly defended, compromise was more likely with real
physical consequences.
IoT threats are real
Threats have
through IoT:
been
executed
Nearly two decades ago, a disgruntled former employee used

network access to remotely
release sewage.
In 2007, researchers demonstrated that a generator could
be destroyed by remotely opening and closing circuit breakers
rapidly.
In 2014, hackers broke into the
industrial network of a German steel mill
and prevented a blast furnace from shutting
down.
With respect to the more modern IoT devices, a researcher hacked his insulin pump,
others managed to compromise smart
meters, and, in a segment aired on 60 Minutes, Defense Advanced Research Projects
Agency (DARPA) scientists remotely controlled automobile brakes.
These examples show how securing billions
more of IoT devices, deploying them on a wide
variety networks, and connecting some of them
directly to the Internet will continue to pose great
challenges.
Even with better network stacks and more
rigorous cyber-security controls, the nature of
many of these devices means that the robust
controls that exist on typical workstations, laptops, servers, or even smartphones are unlikely to be implemented in the devices design.
Controls need to be evaluated and implemented in a different way. Moreover, these devices
are incredibly diverse in application, location,
and architecture. Some rely on centralized con-
trol, while others have their own intelligence and

often operate autonomously.
By definition, they are connected with other
networked components, which means they are
at risk of being compromised, have the potential
to spread infections, and serve as a platform for
hackers to attack other parts of the ecosystem.
That is why the risks posed by IoT are significant, because, normally, there is a level of trust
that pervades the network where these live. It is
the network and its scalability offer the greatest
promise and the greatest risk for IoT.
Figure 1 shows the

cycle of how IoT software interacts with connected devices, akin to
a control engineering
process. Courtesy:
Leidos Engineering
Approaches to IoT risk
So given the wide variety of devices and their

influence on the future world, whats the best
way to reduce risk? Traditional risk management
may point in many directions. Trying to understand the kinds of future threats and devising
controls to address them are likely to be overwhelming with the proliferation of new devices and continual acceleration of related threats.
Also, the traditional strategy depends on how
devices are used.
Another method would focus on the impacts
and prioritize efforts around those with the most
devastating consequences. This is a common
www.controleng.com
digital edition
EXCLUSIVE
or control system computer banks),
whether the devices will interact with
existing technology, and any assumptions that are made about the infrastructure that should already be in
place. All business objectives should
be noted, because one of the tasks
for a risk analysis is to determine the
consequences of those objectives not
being met due to hacking or some
other device failure.
It is also important that a use case
be created for each variation. For
example, connecting a smart meter
that merely measures and reports energy usage has very different implications than one that also supports the
ability to remotely disconnect power.
The details matter. Deciding how
detailed the use case should be is often
a judgment call.
Prioritize vulnerabilities
Figure 2 shows the risk

formula for the Internet
of Things. Courtesy:
Leidos Engineering
method used by many government approaches,

where the bulk of the focus is on impact and not
how vulnerable a particular device is to a given
threat. While impact is important, it is more
important to first appreciate what exactly IoT
devices are intended to do. Starting with a use
case analysis also demonstrates what the intended business purpose is. If a device later gets used
for something else, the risk team can point to the
original analysis to remind management that a
new risk analysis is warranted.
Building a risk model
To evaluate IoT risk, first define the use case.

How will the devices and the supporting infrastructure be used? While technical descriptions
are useful, the focus should be on the relevant
business processes and expected outcomes. How
exactly will this produce operational, business,
or personal value? Given that nearly all projects
must be approved with similar justification, this
information shouldnt be hard to find.
Unlike broad-based budgeting that seeks a
general goal, but doesnt touch on the how, these
use cases should be very specific and should
include details. The kind of data involved should
include whether humans will interact directly
with these devices in a physical sense (such as
health monitoring devices, self-driving vehicles,
DE-29
Once impacts are known, the

potential vulnerabilities are easier to
identify and prioritize. Identification
of vulnerabilities usually starts with
examining all interfaces and potential attack surfaces, both logical and
physical. Because the number is often quite
large, it may be necessary to focus on likely and
sufficiently impactful threats. For example, its
unlikely that a nation state is interested in gathering information on someones power usage
unless it was the power usage for a key military base. In essence, vulnerabilities, to some
extent, need to be informed by the current threat
environment.
Finally, the exercise goes beyond the standard
risk analysis to recognize that IoT will not stand
still. By its very nature, it will grow and mutate
to satisfy demands. Technologies like road sensors and smart meters are not designed to be
replaced frequently, so software updates and network changes will need to use the installed hardware. That also means that considerations like
upgradeability and extensibility, while not largely cyber security considerations, become bigger
issues with IoT. Consequently, future use and
misuse cases should be identified.
Similarly, the consequences of expanding the
network of devices, and how that could lead to
an overreliance on the core installation, need to
be considered. For example, handling the security of a few self-driving cars may be manageable with one person manually doing occasional
oversight. However, once the few cars grow to
several thousands, just hiring more people wont
work, as the amount of data and attack surfaces increase exponentially. In that case, the only
cyber-security solution to greater degrees of
scale and automation is by using cyber-security automation that is then overseen by people.
Harm to other stakeholders, or externalities, also
needs to be part of the equation. The result is the
extrapolated risk that a given IoT device or set of
devices poses, as depicted in Figure 2.
Mitigating risks
Of course, identifying risks is only part of the

equation and is often a trivial exercise. IoT phenomenon has fostered a cottage industry pointing
to all the ways devices can be hacked. While the
potential consequences of these attacks are not
always fully appreciated, its clear that adequately addressing the vulnerabilities will be a big job.
Perhaps the most important consideration is
that the device be identified for a particular purpose and if that purpose changes, the risk analysis and potential compensating controls would
also change for the manufacturer and the end
user. For example, a networked drone could
be sold as only appropriate for agriculture and
oil drilling observations in unpopulated areas.
Enforcing these parameters could be a challenge, even if manufacturers disclaim liability
for unspecified uses.
Vendors have every incentive to find new uses
for products. Moreover, when a device is designated for only a particular purpose, the manufacturer actually may incur more liability as
any failure or harm it caused could be viewed
as foreseeable, an important consideration in
determining negligence. At the very least, some
assumptions should be highlighted, and any limitations should be noted.
For individuals or businesses purchasing these
devices, mitigation and proper use starts with a
well-defined use case development process. For
businesses, that should mean policies specifically
permitting or excluding a devices use in a particular environment or for a particular purpose. Where
personally identifiable information is involved,
there should be clear data collection and retention
policies. And specific people should be assigned
responsibility for each device, as well as for the
larger system involved, where relevant.
Companies, in particular, need to review
insurance for coverage of device damage and the
harm that could result if the device is misused.
Where possible and relevant, some sort of ongoing security monitoring should be implemented.
Finally, device owners need to understand that

one security review is not enough. They need to
schedule ongoing reviews as device use expands,
as major changes are made to any backend infrastructure that communicates with these devices,
and as new types of data are collected. The risk
management model then needs to be revised with
every change in scope.
Six IoT risk mitigation steps
For those currently involved with IoT, which

includes nearly everyone, six basic actions
should be taken regardless of the risk involved
or the dollar amount being spent on the
program.
1. Beginning right away, IoT ownPersonally
ers should identify current IoT impleidentifiable
mentations that are in place, planned,
or anticipated. This may include buildinformation
ing management systems for heating
requires clear
and air conditioning or even the mechadata collection
nisms used to run the elevators if theyre
networked.
and retention
2. Next, organizations should identify
policies; assign
any security policies or procedures related
to IoT. If none exist, companies should at
specific people
least document some high-level controls
responsibility for
that should be in place, such as locking
the elevator machine room.
each device and
3. Within three months, organizations
larger system.
should ensure that device owners have
applied the risk model described above
and reviewed the results with management.
4. Organizations should also identify mitigation steps and associated costs to achieve the
desired state.
5. And in the next six months, organizations
should identify IoT risks that they dont control,
but that affect their organization.
6. Organizations should also participate in industry groups to encourage development of security
standards for the devices that most affect them. ce
- Gib Sorebo is chief cyber security technologist at Leidos Engineering. Edited by Eric R.
Eissler, editor-in-chief, Oil & Gas Engineering,
eeissler@cfemedia.com.
Consider this...
As IoT spreads to almost every object in the future, how
can we protect ourselves from hacked devices, or even
the hacking of our homes? The question is should there
be objects that are not connected for our own safety?
Go Online
Industrial Internet of Things needs data, clouds, and analytics
Linked to this article online: Industrial Internet of Things needs data, clouds, and analytics.
www.controleng.com
Daniel Ackmann ...........37
Amanda Pelliccione, Project Manager and Director of Research
Chad Albert...................37
Corey Arrick..................37
Joseph Bastone ...........37
James Couto ................38
Dave Denison ...............38
Stephen Dora...............38
Jesse Dorn ...................38
Alfredo Flores ..............39
Michael Gagne.............39
Cassy Gardner .............39
Miguel Gutierrez ..........39
Bryant Jackson ............40
Robert Jardel ...............40
Jayesh Jariwala ...........40
Scott Lawless ...............40
Hunter Longshore ........41
Sean Mascarenhas ......41
Abid Munawar ..............41
Justin Nielsen ..............41
Jayson Pestow ............42
Jeff Poirier ....................42
Justin Robinson ...........42
Carl-Johan Roos .........42
Kori Shane ...................43
Lee Smith......................43
Bret Van Wyk ...............43
Chris Vitale ...................43
Nathan Wingate ...........44
David Ziskind................44
36
The 2015 Engineering Leaders Under 40 are a dedicated group

of engineers that give hope to the future of manufacturing.
With the future of manufactur-
ing heavily relying on the younger workforce, Control Engineering and Plant
Engineering are honored to present the
2015 Engineering Leaders Under 40. These
30 individuals are involved in a variety of
industries and responsibilities that force
them to sharpen their multi-tasking and
management skills daily.
The majority70%serve the engineering and system integration (SI) sectors, while
instrumentation and measurement (57%),
consulting (50%), and food, beverage, and
tobacco (50%) round out the top four segments in which they are involved.
Here is a quick look at this years Leaders:
Education: 90% of the Leaders have
earned their bachelors degrees, 20% masters degrees, and 7% associates degrees.
Job function: 23% are primarily involved
in SI roles, 17% control engineering, 10%
general/corporate management, 10% consulting, 7% product design, 7% manufacturing engineering, and 6% plant
management/engineering.
SI or engineering services: 79% provide

SI or engineering services to manufacturing organizations.
Products or systems: The top five products or systems purchased or specified by
this years Leaders are industrial control
equipment or systems (57%), software
(53%), I/O products or systems (53%),
instrumentation (53%), and programmable
logic controllers (53%).
Machines for resale: 37% design, build,
or install machines for resale to other
companies; 47% design, build, or install
machines for use within their companies.
The 2015 Engineering Leaders Under
40 are featured in the following section and
with more information online at
www.controleng.com, and will be honored at
the 2016 Engineering Awards in Manufacturing dinner hosted by Control Engineering
and Plant Engineering on Monday, March
21, 2016, in downtown Chicago. For information on how to nominate for 2016, visit
www.controleng.com/EngineeringLeaders.
Daniel Ackmann, CEM, LEED AP BD+C, 28
Chad Albert, 30
Project Manager; Energy Engineer; Enviro-Management &

Research Inc.; Springfield, Va.
Engineering Manager;
Bluff Manufacturing; Fort Worth, Texas
BS Civil Engineering, Purdue University
BS Civil Engineering,
Western Michigan University
ckmann enjoys the nonroutine nature of working with multiple

federal agencies, of helping find out-of-the-box solutions to
save energy and money, and of having a considerable indirect impact
on so many people. He has consulted for federal agencies looking to
optimize performanceincluding the U.S. Dept. of Defense, where
he assisted in achieving federally mandated energy and greenhouse
gas (GHG) reduction goals, developed and maintained GHG inventories, analyzed utility bills and rate structures for opportunities to
lower costs, and identified energy conservation capital investments
and lower cost opportunities. In response to the American Energy
Manufacturing Technical Corrections Act of 2012, Ackmann was the
lead writer and researcher in identifying advanced meter best practices in federal facilities, buildings, and equipment for the U.S. Dept.
of Energy. Ackmann manages the development and operation of the
Architect of the Capitols utility metering enterprise system and bill
verification system to ensure that all U.S. Capitol facilities effectively
manage energy use and retain data to establish near- and long-term
utility budget goals. Ackmann has authored federal guidance for procuring public utility and energy management services through area
wide and utility energy service contracts for the General Services
Administration. Recently, he and his wife vacationed in Iceland to
enjoy the people, geology, and beauty of the country.
Corey Arrick, 38
Joseph Bastone, 37
Engineering Manager, BAE Companies,

Philadelphia
Marketing Manager; Honeywell;

Fort Washington, Pa.
BS Agricultural & Biological

Engineering, Purdue University
BS Chemical Engineering,
Rensselaer Polytechnic Institute
rrick has broad experience as

a process engineer and project
manager working in the food, pharmaceutical, and health/personal care
industries. He has worked as a design and construction engineer for
various clients, ranging from Godiva Chocolatier to GlaxoSmithKline.
He also has worked in plant operations and as a quality specialist in
the meat industry. Recently, Arrick managed the operations team and
acted as the start-up engineer at a meat import and processing facility. He manages the quality department for the companys products,
achieving U.S. Dept. of Agriculture import and domestic status and
leading the facility to Safe Quality Food certification. In 2001, Arrick
received an Operational Achievement Award at Godiva Chocolatier
for the installation and start-up of a caramel-cooking process, and
in 2012 he received a PRIDE AwardProfessionals Recognizing
Individuals who Demonstrate Excellenceat Barry-Wehmiller Design
Group. Arrick has five U.S. patents and two European patents for
hot-beverage products. Arrick is a motorcycle enthusiast and enjoys
experimenting with foods and drink by brewing his own beer, wine,
and ciders and making his own yogurt and cheese.
lbert brings his advanced

skills in creating automation
systems for the engineering team at
Bluff Manufacturing. As an innovator,
Albert drives new product development and redesigns existing products for greater manufacturing efficiency. He consistently leads his
team to deliver solutions and value to their customers, increasing revenue for his company. Albert has transformed the way Bluffs products are created with his process development framework designed
for the engineering department. He also has created automated
tools to streamline the customer ordering process and systematize
products, resulting in decreased ordering cycles. In the engineering industry, Albert has been the Bluff member representative of the
Loading Dock Equipment Manufacturers group of the Material Handling Institute, which reviews, discusses, and revises the standards
for the design, performance, and proper operation of loading dock
equipment. Outside of work, Albert enjoys spending time with his 2and 4-year-old sons. He is involved with community service, including
mission trips to Central America and helping with Hurricane Katrina
cleanup in Alabama. Albert volunteers for his church through community cleanup projects and assisting the homeless in Fort Worth.
astone uses his strong analytical capabilities to consistently

prioritize tasks for effective commercialization of prominent developments
at Honeywell in Fort Washington, Pa. He manages the Experion PKS
Control and I/O portfolio, which includes five product manager direct
reports who represent more than 100 years of experience. Starting as
an application engineer, Bastone spent his first 8 years with Honeywell in the field with key customers. He later joined the product marketing team as the product manager for Experion controllers and was
selected to launch derivatives of Experion PKS, for which he received
a Corporate Marketing award in 2012. Bastone is now the marketing
manager for this product, and he recently launched the Universal I/O
for Experion. He is also a key contributor for the LEAP initiative at
Honeywell Process Solutions, challenging how automation projects
are implemented and deployed. For this, he also won a Corporate
Marketing award in 2015. Bastone always has been drawn to technology and the path it offers: exposure to new, high technologies while
managing a business. At home, he does time-lapse photography with
his two children, along with a student robotics platform.
www.controleng.com
James Couto, 32
Dave Denison, 39
Project Manager; Autopro Automation

Consultants Ltd.; Calgary, Alberta
Director, DeltaV Product Marketing;

Emerson Process Management;
Round Rock, Texas
BS Electrical Engineering, Lakehead

University; MBA, University of Calgary
BS Computer Engineering, Iowa State

University; MBA, St. Edwards University
outo is currently the youngest

project manager contracted at
Autopro Automation Consultants.
Couto also manages his own company, Couto Consulting, and a separate software-as-a-service business.
He is recognized at Autopro as a strong leader and an effective team
builder, and he is always looking for ways to improve processes and
drive efficiency in projects. Coutos broad range of skills and experience, including an excellent balance of people and technical skills,
contributes to his tremendous ability to mentor others, even staff
members more senior than he is. In the past year, Couto successfully
completed his MBA at the University of Calgary, an achievement that
consumed all of his spare time. The desire to broaden his experience
and move away from a pure technical focus to one that includes the
business perspective prompted him to pursue the degree independent of financial support from the company. Off the clock, Couto volunteers with Engineers Without Borders and works on the corporate
engagement team to establish awareness of the organization. He
participated in the 2012 Enbridge Ride to Conquer Cancer and raised
more than $5,000 for the Alberta Cancer Foundation.
Stephen Dora, 33
Jesse Dorn, 32
Engineering Specialist, Plant Planning;

Toyota Motor Engineering & Manufacturing North America Inc. (TEMA); Erlanger, Ky.
Project/Maintenance Manager,
Manufacturing; Victaulic; Easton, Pa.
ver the past 16 years at Emerson Process Management,

Denison collaborates cross-functionally to create a compelling product and technology vision based on
customer needs and new innovations. He contributed to the DeltaV
distributed control system (DCS) as a software engineer, software
development manager, and director of software applications and is a
DeltaV product marketing director. Denison wrote real-time software
responsible for running control logic and interfacing to multiple I/O
technologies within the DeltaV controller. Denison led the effort to
design and certify the DeltaV SIS with the Electronic Marshalling
product. Denison is a recognized innovator and has been awarded
seven patents associated with DeltaV. Denison planned and directed
multiple programs within the product areas of operations environment, engineering clients and servers, virtualization, and remote
monitoring. Denisons move into product marketing has increased his
responsibilities and ownership of the DeltaV product lifecycle. During
free time, Denison plays softball, basketball, and golf, and coaches
his daughters youth basketball team.
BS Electrical Engineering,
Rose-Hulman Institute of Technology
AAS Tool Making Technology & BS Manufacturing Engineering,

Pennsylvania College of Technology
ora demonstrates leadership

in his role as project leader for
the TEMA Plant Planning Section
for specification, design, construction, and handover as the owner
for Toyota manufacturing plants in North America. At Toyota Motor
Manufacturing Kentucky he exhibited continued growth in leadership
roles for plant expansion to bring the Lexus brand to the U.S. Dora
has advanced from his background of electrical engineering through
building components and systems, including civil/structural, mechanical and piping, and electrical power and distribution. He has brought
and led innovative cost-effective design and construction improvements while Toyota budgets and schedules have compressed. He
participates in seminars and conventions to continue professional
development. Dora is a leader for Toyota projects primary commitment to construction safety by obtaining his Occupational Safety and
Health Administration 30-hour credentials as well as participating in
all Toyota electrical safety and lockout training. He has authored several Toyota training courses on power distribution and electrical systems. Dora married in July 2015, and he and his wife enjoy running 5
and 10k races, traveling, and yard saling.
38
orns intelligence, self-motivation, and professionalism

has allowed him to be successful
in multiple roles within Victaulic, including his present position as
the project/maintenance manager in manufacturing. Dorn began
his career at Victaulic in 2007 in the rotational engineering program
and has rapidly advanced while undertaking various leadership
roles. He has served as a cost reduction team leader and municipal
operations facility manager to his current position. With a strong
understanding of U.S. operations, Dorn has been instrumental in
implementing effective process improvements that have enabled Victaulic to achieve major savings while boosting productivity, improving
manufacturing output, and enhancing on-time product delivery for
customers. Dorn is skilled in process improvement, including finding
ways to secure local efficiency gains and manufacture products close
to customers. He has a strong passion for locomotives, specifically
fixing and performing maintenance on steam trains. He volunteers
at several tourist railroads. When not working on trains, Dorn likes
spending time with his wife, two children, and other family; out on the
river in his kayak; or riding dirt bikes and four wheelers with friends.
Alfredo Flores, 31
Michael Gagne, 28
Senior Controls Engineer; RedViking;

Plymouth, Mich.
Senior Software Engineer; Kepware Technologies; Portland, Maine

BS Electrical & Computer Engineering, University of Maine
BS Mechatronic Engineering,
Monterrey Institute of Technology and
Higher Education, Quertaro (ITESM)
lores is a detail-oriented leader

in implementing standards that
unify RedVikings processes across
diverse business units. From his origins in mechanical design, Flores
has shown aptitude for quickly acquiring new skills and leads in
electrical engineering, controls engineering, and project management
for the manufacturing execution systems (MES) and manufacturing
and assembly solutions teams. At age 25, Flores took over a factory
information systems launch project with great success. At 27, he
managed a staff of eight engineers to successfully implement a complete tracking and error proofing system (EPS) in a new plant, before
conveyors were installed. Flores EPS worked flawlessly upon launch
without time for the normal debugging process. He recently designed
a unique controls architecture for RedVikings battery-free inductively
powered automated guided vehicle system, Wingspan. Flores is the
new knowledge leader and has designed a new approach to make
the AGVs controls-agnostic. In his free time, Flores is studying for
his Masters degree in engineering management and enjoys playing
outdoor sports with his two young children.
agnes extremely versatile skill set allows him to lead projects

in all of Kepwares major markets. He is well respected among
his peers, serving as a mentor to new hires and contributing to key
decisions behind Kepwares major product releases. In 2009, Gagne
was one of the first recipients of Kepwares Scholarship for Excellence in Engineering. This recognition led to an internship with the
company followed by his graduation in 2010. From there, he quickly
advanced his career, moving from software engineer to senior software engineer. Gagne played a major role in the design and development of the Scheduler, a data optimization tool integrated within the
companys flagship product, KEPServerEX. As lead engineer of the
project, he ensured the technology maintained its core purpose and
functionality from inception to release. His ability to contribute across
many areas of the business makes him an invaluable asset to the
company and enables him to lead future initiatives. Currently, Gagne
is spearheading the development of Kepwares OPC Unified Architecture implementation. Gagne also promotes science, technology,
engineering, and mathematics (STEM) education by volunteering in
local career fairs, encouraging students with his own story to pursue
careers in technical industries.When hes not overseeing engineering
projects, Gagne spends free time homebrewing his own craft beers,
having recently joined the American Homebrewers Association.
Cassy Gardner, 24
Miguel Gutierrez, 35
Engineer; Banks Integration Group;

Vacaville, Calif.
Project Manager; Maverick

Technologies; Santa Ana, Calif.
BS Biological Systems Engineering,

University of California, Davis
BS History, California State University,

Fullerton
hough Gardner is in an entrylevel position at Banks Integration Group, she has significantly
impacted her company and continues
to help reshape its direction and culture. Gardner is actively involved
in creating a positive environment at Banks; she has taken the lead
role in Bright Ideas, one of Banks managements initiatives aimed at
improving employee engagement. In this role, Gardner has engaged
and collaborated with employees of all levels within her company.
Gardner has developed the infrastructure to help employees make a
positive impact and influence the direction of the company through
this iniative. In addition to her contributions at Banks, Gardner enjoys
working with children to foster interest in the science, technology,
engineering, and mathematics fields. She recently participated as
a mentor in the Women in Science and Engineering program at UC
Davis and helped execute and coordinate an outreach presentation
at the local Boys & Girls Club of America. She actively participates in
the local International Society for Pharmaceutical Engineering (ISPE)
chapter planning and organizing events and also has spoken at the
local student chapter of ISPE about controls engineering.
utierrez combines many

first-rate skills to make him
an effective engineering leader at
Maverick Technologies. He quickly
learned the necessary technical skills early in his career and still
demonstrates an ongoing personal drive to always know more. He
engages with customers to understand their needs and with coworkers to encourage, help, and train them. Gutierrez knows what it takes
to execute a project right the first time with the highest quality, keeping the team focused so that the customer is delighted and Maverick
is the preferred choice for customers and employees. A liberal arts
background forms the foundation of Gutierrezs experiences. However, as he worked through school he acquired database programming
experience that quickly transitioned him into the automation industry
where he found an aptitude for human-machine interface and programmable logic controller development. He has consistently gained
skills and executed increasingly complex projects through his career,
pushing himself to excel in each task. He is a regular contributor to
company blog posts that promote excellent work skills. When hes
not working, Gutierrez can be found at the paintball park with friends
or preparing for his next Zombie Run or dragon boat race.
www.controleng.com
Bryant Jackson, 28
Robert Jardel, 30
Systems Engineer/Task Manager;

Leidos Engineering; Walled Lake, Mich.
Controls Engineer; Airline Hydraulics;

Bensalem, Pa.
BS Electrical Engineering Technology,

Michigan Technological University
AAS Mechanical Engineering,

Camden County College
Jayesh Jariwala, PE, 39
Scott Lawless, 35
Project Manager; Applied Control Engineering Inc. (ACE); Owings Mills, Md.
Project Manager; Leidos Engineering;

Walled Lake, Mich.
University of Delaware
BS Electrical Engineering & Computer

Engineering, Kettering University
ackson is an eager, capable

young professional who has
quickly risen at Leidos because of his
outstanding talent and aptitude. His
ambition is apparent to all that work with him. Jackson enjoys a challenge and volunteers for new and difficult responsibilities, resulting in
him quickly becoming a leader within Leidos as a systems engineer
and project manager. He is willing to tackle any task, running straight
toward a problem to find the solution. Jackson was hired at Leidos
immediately following his graduation from college in 2010. He took
on additional responsibilities, even outside the expectations of his
managers. He is most proud of his work at a casting facility in Toluca,
Mexicoa very difficult project that he encountered in his career.
He started as the lead project engineer, responsible for the design,
implementation, and commissioning of a new utility control system to
be tied into an energy management system. He is currently the main
point of contact for the majority of this customers projects.Jackson
spends his time away from work with his wife and their 5-month-old
daughter. He also volunteers for philanthropic walks and is active in
other similar events.
ariwala possesses expertise in

classic control systems including
human-machine interfaces and programmable logic controllers. Jariwala
differentiates himself with a breadth of knowledge on plant historians,
database schemas, reporting applications, and custom programming
applications. Strengths include designing systems to capture critical process data and developing dynamic Web-based reports for a
variety of users. He has also worked with customers to bring plant
floor data into manufacturing execution systems and enterprise systems. Since graduating from the University of Delaware, Jariwala has
enjoyed a career as a process control engineer at ACE. He began
his career in ACEs Newark, Del., office and then transitioned to be
a senior technical resource for ACEs Chesapeake Region office in
2010. Throughout his career at ACE, he has been a highly soughtafter resource internally and to ACEs customers. Jariwala is also the
FIRST chair of the Baltimore/Washington D.C. section of the International Society of Automation (ISA). For the past 5 years, he has volunteered as a mentor for the FIRST Robotics Competition. Jariwala
mentors an all-girls robotics team from Western High School in Baltimore, providing programming training and troubleshooting support.
40
ardel is the type of person who

can pick up a book or manual,
read it, and retain all the knowledge
inside. He is self-motivated, hardworking, and is always willing to go above and beyond to help and
teach others in his spare time. Jardel quickly expanded his skill set
when he started with Cryovation LLC in 2013, which resulted in company growth. He was quick to put his acquired skills to use, helping
to develop new processes for the company; this led to the release of
two new products that Jardel designed. Jardel also took leadership
roles in a number of startups, interfacing with multiple engineering
disciplines, salesmen, as well as the customer. Currently, Jardel
is employed with Airline Hydraulics where he hopes to once again
develop and implement innovative solutions for a growing industry. At
home, Jardel has set up a programmable logic controller (PLC) test
station with human-machine interfaces, PLCs, and other automation
controls in order to develop his skills and discover new techniques for
his profession. Even though his work finds its way home every night
he never misses an opportunity to spend quality time with his fiance,
Katie, and daughter, Caylen.
awless is a project manager

and engineer who consistently
performs and completes projects
successfully, gaining him the trust,
confidence, and respect of his clients. Lawless has developed profitable programs for major customers at Leidos Engineering and is a
leader in his part of the company. Lawless strengths lie with implementing system integration program solutions and teaching young
engineers within Leidos. His team is currently working on a fan array
air handling system program that is developing a standard control
system design to meet the requirements of his clients, Ford Motor
Co. and General Motors. His team is in the process of designing a
modular chilled-water control system that can be assembled and tested before shipment to the clients site. Lawless is a certified energy
manager through the Association of Energy Engineers and a project
management professional through the Project Management Institute.
Within the company he is a go-to person for system controls/integration questions and assistance. Lawless is close with his family and
friends, well connected, and respected in the community. He has
been involved with multiple kickball tournament fundraisers and local
charities and has a great camaraderie with his coworkers.
Hunter Longshore, 33
Sean Mascarenhas, 33
R&D ProfessionalControl Systems

Engineer; Sandvik Mining; Alachua, Fla.
Senior Engineer; Autopro Automation

Consultants Ltd.; Calgary, Alberta
University of Florida
B.Eng. Electrical Engineering,

McMaster University
Abid Munawar, 33
Justin Nielsen, 37
Central Engineering Lead; Intech

Process Automation; Houston
ManagerControl Systems &

Instrumentation; Excel Engineering;
St. Paul, Minn.
ongshore is a talented, detailoriented, and hands-on control

systems engineer at Sandvik Mining. Having taken a system lead
role at the Sandvik Automation Modules (SAM) product line, he has
responsibility for upgrades, rollouts, investigating issues, providing
hot fixes, and other primary tasks related to SAM. Additionally, he has
undertaken mine visits where he engages the end user to suggest
new features and capabilities as well as conducting troubleshooting
and training sessions. Longshore has led several training classes
within the Sandvik factory in Florida to educate shop floor personnel
whenever new features are released and on testing. While studying
at the University of Florida, Longshore found a genuine interest in
mechatronics and dedicated one of his senior projects to developing
closed-loop control motor driver boards for a three-axis computerized
numerical control machine. Additionally, during his college career,
he spent a couple of summers in South Africa working at a robotics
lab where he was introduced to machine controls. Aside from work,
Longshore is also an avid cyclist and runner, often training with his
co-workers for off-road cycling events and half marathons.
BS Mechatronics Engineering, National

University of Sciences and Technology;
MBA, Virtual University of Pakistan
ascarenhas has progressed

very quickly since graduating
from McMaster University. He was
responsible for major projects very
early in his careerwithin his first 5 years he led a large distributed
control system upgrade project, including a successful shutdown and
turnaround. When Autopro opened its location in Pune, India, Mascarenhas was one of the first people sent to train and mentor new
technical staff, working long hours to orientate them and get them
ready to work on Autopros projects. More recently, he was electrical
lead on a large greenfield project for a major petrochemical producer,
the largest project in Autopros 25-year history. This involved managing a team of more than 20 technical staff, in addition to interfacing
with the client and subcontractors, and ensuring that quality standards were met on all electrical deliverables. There was a great deal
of complexity in the number of engaged vendors, number of Autopro
branches that provided project staff, and new technologies that were
deployed on the project. For the past 6 years, Mascarenhas has volunteered as a high school football coach. He loves football and sharing his passion for the game to develop leadership skills with youth.
Clarkson University
unawar has demonstrated

leadership skills required at
a management level to achieve his
career goals and to contribute in achieving company targets. He is
continually striving to enhance his professional skills so that his team
can improve as a whole. Munawars main contribution has been in
establishing a central engineering lead function and managing a
large pool of project resources. He has developed and successfully
run batches of trainee engineers to harvest resources for meeting
Intechs future needs. Munawar has established an effective performance management mechanism to not only evaluate performance
periodically but to chalk out a career road map and provide mentorship to younger engineers so they can achieve their objectives. For
this, he formulated a new competency framework for his business
unit by using his analytical skills and mapped the existing competencies of the resources of his department on the new framework for gap
analysis. Munawar has led a volunteer group that planted and cared
for more than 3,000 trees in Lahore, Pakistan. He recently relocated
to Australia and is looking forward to contributing to its automation
and control society.
ielsen has provided a fresh

perspective to broaden the
services provided by Excels Control
Systems group, as well as the client base that Excel Engineering
serves. He is able to understand what the client needs, ensure that
the individuals performing the work are performing optimally, and
provide quality services to Excels clients. He has a vested interest
in sharing his knowledge with the engineers who work with him and
helping them succeed in their careers. Nielsen has been involved in
controls and automation engineering since 1999 and has a strong
background in the pharmaceutical, chemical, and power generation
industries. Nielsen has been the lead for control system engineering
on several multi-million dollar controls system upgrade projects for
key clients. Nielsens functions include developing new business relationships, mentoring junior level engineers, and continuing to broaden
the services that engineers can provide. Nielsen is an International
Society of Automation (ISA) member and an ISA-certified automation
professional. Nielsen is a dedicated father of two boys, who are 7
and 9 years of age. He enjoys coaching their baseball and basketball
teams and participating in activities that capture his sons interests.
www.controleng.com
Jayson Pestow, 31
Jeff Poirier, 39
Senior Controls Engineer, Functional

Safety Engineer (TV Rheinland);
Frakes Engineering; Indianapolis
Senior Controls Engineer;

RedViking; Plymouth, Mich.
BS Automation & Control Engineering,

Indiana State University
estow is very passionate about

machine safety and works hard
to help customers achieve a safer
facility. While in high school, Pestow participated in a 2-year technical program for machine tool technology and was inducted into
the National Vocational-Technical Honor Society. After graduating
college, Pestow maintained his commitment to the constant learning curve in engineering and technology. As a young engineer, he
earned his Six Sigma Green Belt and used those tools to lead Lean
initiatives for several years. Working as an engineer comes with
inherent risk, and being a witness to two nonfatal industrial accidents propelled him into the concentration of machine safety. Frakes
Engineering shares his commitment to safety and presented him the
opportunity to pursue a certification as a functional safety engineer
through TV Rheinland, a certification that fewer than 100 engineers
nationwide receive each year. Pestow has been a competitive runner
and triathlete for 6 years. In 2012, he proposed to his now-wife, Tara,
at the finish line of his first marathon. This past May he was a top-500
finisher in the Indy 500 Mini-Marathon, a large U.S. half-marathon.
Justin Robinson,
PE, CAP, 30
Performance Excellence Specialist;
Maverick Technologies; Columbia, Ill.
Auburn University
obinson has experience working in an array of industrial

manufacturing industries, on various distributed control system (DCS) platforms, and in multiple
roles on Maverick project teams. Robinson has led significant DCS
and human-machine interface migration projects. He also supports
coaching and mentoring of team members, and he is the subjectmatter expert of high-performance graphics within Maverick, supporting the technical leadership of projects. Robinson started his career
with Maverick as a process control engineer. He has since been
promoted from engineer I, engineer II, and senior engineer to a principal engineer within 7 years due to his technical expertise, leadership, and customer support dedication. Robinson was most recently
promoted to a new role as a performance excellence specialist.
Robinson says that learning new things is the most fulfilling aspect of
this career. Professionally, he enjoys learning coding, languages, processes, controls platforms, or work processes. When he is not working, Robinson enjoys playing guitar with his churchs worship band as
well as expanding his cooking and handyman skill sets.
42
University of Michigan
oirier designed first-of-its-kind

helicopter transmission flexible
testing software at RedViking that
enables motors to switch roles during and between tests to accommodate highly complex test profiles
on one test stand. The challenge of configuring four 3,000-hp motors
to change roles was unprecedented. In an example of a typical helicopter test stand, Motor A might always control speed with Motor B
slaved or geared to follow it with balanced torque. Motor C creates
load, and Motor D absorbs load and syncs to the first two motors.
And all of these have to be synced and balanced. Poirier has built
software to allow the test operator to change the system at the push
of a button, so that the speed is now controlled by Motor C and
torque is controlled by Motors A and D. In the same test or in the
next test speed can be controlled by Motor B and torque by Motors
A and D. Poiriers software creates previously impossible flexibility in
helicopter powertrain testing and provides outstanding cost savings.
Poirier is an avid mountain biker; while on his honeymoon in Hawaii,
he and his wife rented road bikes and used them to climb to the top
of the Haleakal volcano, an 83-mi ride with 10,700 ft of climb.
Carl-Johan Roos, 34
Functional Safety Officer;
Emerson Process Management,
Rosemount Division; Shakopee, Minn.
M.Sc. Electrical & Computer
Engineering, Chalmers University of
Technology; MS Electrical & Electronics
Engineering, Georgia Institute of Technology; MBA, University of Gothenburg
oos was one of the driving forces behind a new standard for
overfill prevention that has been a major safety contribution to
the oil industry. Roos has built-up a global overfill prevention business with unique competency based on thousands of installations.
This know-how is now used in a customer-centric approach where
Emerson provides the global process industry with the equipment,
solutions, and lifecycle services compliant with functional safety standard IEC 61511 to minimize the overfill risk. Roos has led the extension of modern level measurement technologies into safety-critical
applications. He has contributed significantly to product achievements at his company, including taking safety to the next level by
introducing the worlds first SIL 3 radar level gauge, reducing installation costs considerably through a patented two-in-one radar level
gauge, and introducing new proof-testing technologies, such as verification reflectors. Outside of work, Roos is a fanatic floorball player,
which can be described as hockey but without the ice and the skates.
He and his wife have two sons, ages 9 months and 3 years old.
Kori Shane, 38
Lee Smith, 30
Safety and Environmental Manager;

Schneider Electric; Cedar Rapids, Iowa
Lead Software Engineer; Mettler Toledo

Safeline Ltd.; Manchester, England
BS Environmental Health,
Illinois State University
MS Software Engineering,
The University of Manchester (UMIST)
Bret Van Wyk, 32
Chris Vitale, 38
Program Manager; Interstates Control

Systems Inc.; Sioux Center, Iowa
Director of Marketing;
Turck; Plymouth, Minn.
BS Computer Science & Systems Administration, Dordt College
Minnesota State UniversityMankato;
MBA, University of Phoenix
hane is an integral part of

the management team in the
Schneider Electric Cedar Rapids
facility, providing leadership in the
locations direction beyond her primary function of leading safety and
environmental activities. She is the leader of the plant safety committee at her facility and a member of the plant emergency response
team. Shane has led the campaign for safety-improvement ideas
as well as developed and implemented the plants behavioral safety
audits. She was responsible for implementing the use of active
release technique in her facility; a technique that proactively treats
injuries to prevent them from becoming serious. She is also leading
the development of the facilitys business continuity planan action
plan that actively anticipates the impact that a crisis or disaster could
have on a plant. Shane is the North American representative to the
GlobES Phase II Steering Committee, which integrates the global
processes for safe chemical management. Beyond the plant walls,
Shane drives to take safety and environmental aspects into her
home. She has a passion and dedication to her children and works to
raise them in a safe and healthy environment.
an Wyk is a key resource

in working with Interstates
customers to find solutions for
supervisory control and data acquisition (SCADA) computer systems, industrial networks, and hosted
virtualization platforms. Van Wyk is a leader in the companys
manufacturing information technology (MIT) services group, and his
primary responsibility is in the quality of project delivery. Van Wyk
began his career with Interstates as an MIT systems analyst and
has assumed additional responsibilities over the past several years.
He has been heavily involved in developing an industrial patching
solution for a Fortune 500 company that services all plant floor PCs.
This process includes analyzing the software on the system and
offering approved Microsoft patches accordingly. Van Wyk is now an
Interstates program manager. In this position, he is responsible for all
projects within MIT, as well as developing internal work processes for
his team. Van Wyk is driven to find ways to continually improve his
work. Because of Van Wyks push, the MIT team has made progress
in documentation, efficiency, and work accuracy. Outside of work,
Van Wyk enjoys learning how to use his new meat smoker. He enjoys
spending time with family and playing with his kids.
mith is a lead software engineer

for Mettler Toledos metaldetection business. Based in Manchester, England, he has strategic
and technical ownership of the connectivity and machine-integration
capabilities for all metal-detection products. In addition, he has
responsibility at a divisional level to define a harmonized approach
to connectivity and machine integration across all of Mettler Toledos
product-inspection systems. Smith is one of Mettler Toledos Organization for Machine Automation and Control (OMAC) representatives
and is also a member of the PackML Technical Advisory Board. He
holds a masters degree in software engineering from UMIST and is
an elected Chartered Engineer on the UK Engineering Council. Smith
recently presented at the OMAC PackML workshop in Chicago where
he provided a case study of Mettler Toledos PackML implementation
as well as examples of how to use PackML in combination with various industry standard protocols to offer customers a true end-to-end
integration solution. Smith and his wife spend free time with their
three young sons, including a recent visit to the Chill Factore indoor
snow parka new experience since the U.K. doesnt get much snow.
uring his 15 years with Turck,

Vitale has demonstrated a
deep understanding of how their
products work and make a difference in the field. He has a passion for educating others about Turck technology and how it can be
applied. He is constantly searching for ways to evolve this skill, most
recently transitioning from a role as product manager of Turcks network and interface division to serve as director of marketing. Vitale is
skilled at connecting and creating conversations between end users
and engineers, and he continues this tradition in his current position.
Vitale has helped guide many products from concept to installation
in customer applications, including Turcks Multiprotocol Ethernet
technology platform. After 6 years in the division, Vitale transitioned
to lead the marketing department as its director in December 2014.
He saw this as an opportunity to apply his product knowledge and
engineering mindset to the creative design and marketing skills of the
team. Outside of work, Vitale spends as much time as possible being
outdoors and with his family. His hobbies include hunting and fishing,
working out, family bike rides, and playing sports like Wallyball and
basketball.
www.controleng.com
Nathan Wingate, 26
David Ziskind, PE, 33
Utilitiesand Technology Manager; Cooper River Partners; Goose Creek, S.C.
Automation Engineer;
The Dennis Group LLC; Duluth, Ga.
BS Mechanical Engineering,
University of North CarolinaCharlotte
Georgia Institute of Technology
ingate exhibits the technical

and analytical skills of a competent engineer and positive character and moral foundation apparent to
all who work with him. He has a logical sense of what is required of
engineered systems, the analytical engineering knowledge to test his
intuition, the curiosity to delve into working details, and the engineers
fulfillment of accomplishment when his involvement has resulted in
a more efficient and safer plant operation. Wingate began his career
as a maintenance engineer and advanced to utilities and technology manager, which includes management of all operational utilities,
process control systems, and information technology. Wingates diligence have contributed to an overall utility uptime of 99.97% for three
successive years in a facility that operates round the clock. Wingate
applies analysis skills to guide problem solving and drive corrective
action through the maintenance department and capital projects.
Wingate understands that his professional and family responsibilities
are intertwined. He is a leader in his community and church with a
deep interest in promoting missions to help underprivileged people.
eyond his direct automation

and electrical engineering
responsibilities, Ziskind leads
recruiting efforts for The Dennis
Groups Atlanta office, which has seen personnel growth of more
than 60% over the past 2 years. Part of this strategy includes building relationships with more than eight colleges, universities, and
trade schools. Additionally, Ziskind has built a co-operative program
from the ground up, a program which now has more than 10 co-op
participants performing engineering work for the company. Ziskind
started in the industry as a co-op at Polytron in 2001. Six years
later, he managed the companys design group, including rolling
out Autodesks AutoCAD Electrical throughout the organization
and leading the effort to outsource modular design work. Ziskind
led the electrical and startup effort for a major revamp of a cold-fill
beverage line for a Fortune 500 company, successfully leading to
the products market debut. Ziskind enjoys traveling, having visited
South America and hiking the Inca Trail with friends in 2009. Ziskind
and his wife, Miriam, reside in Atlanta with their two sons.
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inside process
How to update an
HMI
Upgrading human-machine interface (HMI)

hardware, software, and applications can be an
efficient process with limited required development
time if these recommendations are followed.
ost manufacturing facilities

use PC-based human-machine
interfaces (HMIs) to operate
and monitor automated equipment. Unfortunately, just about
every one of these facilities has HMI software
or hardware that is, or soon will be, obsolete
(see Figure 1).
Advice is available for how to efficiently upgrading from one PC-based HMI operating system to the next, from one version of HMI
software to the next, or from one HMI software supplier to anotherall while minimizing
rework of the existing HMI graphics, programming, and configuration.
The dreaded operating system upgrade
Typically triggered by a PC hardware failure, upgrading the operating system (OS) on a

PC-based HMI can be difficult for a variety of
reasons. To perform this type of an upgrade, the
issues listed in Table 1 must be evaluated and
addressed.
Usually, the first step is consulting the HMI
software vendor to verify what HMI versions are
compatible with the new OS. However, as technology evolves, many HMI vendors are tempted
to create new products and disregard compatibility
with legacy operating systems.
More often than not, the HMI software originally used to design the application has been discontinued, and to support the new OS, it must be
migrated to different HMI softwarenot just a
newer version of the same software.
If migration is necessary, the application must
typically be re-designed, either partially or entirely, which results in high costs related to engineering and downtime. These costs can be reduced
or even avoided when purchasing HMI software
from a supplier committed to adopting technological evolution while maintaining compatibility with
applications created in previous software versions.
Communication protocols that implement a
proprietary physical layer, such as Data Highway
Plus (DH+), Profibus DP, and others, require a
physical adapter to connect a PC to the proprietary network. Such adapters require custom device
drivers so the OS can recognize them. Migrating
to a new OS usually requires an updated version
of these device drivers.
In the long term, the best approach to avoid or
minimize the risks and costs associated with this
migration is to replace, when feasible, protocols
and networks based on proprietary physical layers
with protocols supporting communication through
standard Ethernet-based networks.
Ethernet has grown as a standard physical
network in automation systems. HMI software
that provides a layer of abstraction or separation
between the communication interface and the tags
database will facilitate the new configuration, and
it will also aid and simplify future upgrades.
The impact on the HMI software project will
depend on the level of isolation that HMI software
provides between the communication interface
Figure 1:
When an HMI gets that
rusty old car look, its a
good time to consider
upgrading the operating system and HMI
software or to select a
new HMI software vendor. Images and tables
courtesy: Wonderware
InduSoft
Key
concepts
Making an operating
system upgrade to a
PC-based HMI can cause
platform problems.
If a change is necessary,
upgrading to a new HMI
can provide a variety of
benefits.
Automatic mechanisms
can make an upgrade
easier by retaining key
functionality.
Table 1: Considerations when

upgrading operating systems and PCs
Operating system incompatibility with existing HMI software
Communication protocols
Device driver changes
Screen resolution
Screen size factors
Touchscreen operation
Physical size and shape
www.controleng.com
CONTROL ENGINEERING SEPTEMBER 2015 P1
inside process
and other interfaces of the project,

such as graphical display and scripts.
More separation or isolation is better.
Hardware migration issues
Looking at extra space on an

HMI screen from a new aspect
ratio? Design one new screen
that is always visible and shows
critical alarms indicators to fill
the gap. Dont forget to consider
mechanical changes.
When upgrading the PC display,

changes in screen resolution can
pose two common challenges. In
the first scenario, a different screen
resolution has the same aspect ratio
(such as migrating from 800x600 to
1,024x768). Some products offer a native feature to scale the
graphical interface automatically, so no modifications are necessary to the original application to fit a new resolution. Other
alternatives would be off-line automated conversion and, in the
worst-case, manual adjustment of the screens.
In the second scenario, both the resolution and aspect ratio
change simultaneously, as when migrating from 1,024x768 to
1,920x1,080 while upgrading to 16:9 wide-screen monitors and
panels. A cost-effective method to mitigate this scenario is to
use the automatic screen scaling capability of the HMI software development platform, if such is available. And, its also
often helpful to design one new screen that is always visible
and shows critical alarms indicators to fill the gap caused by
the new aspect ratio.
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Often overlooked, mechanical changes must be completed in

advance to support the physical size
of the new PC, especially when the
device must fit in a panel door. The
touch screen operation may also
change. The HMI software must
be compatible with the input method of the new station such as touchscreen, physical keys, and/or mouse.
Depending on the original software
characteristics, configuration adjustments may be required for
the application.
Upgrading from one HMI version to the next
There are many functional reasons to upgrade existing HMI

software to a suppliers newest version such as an improved user
interface, added features, and improved communication. Another reason to upgrade is to maintain customer support from the
software supplier, as most suppliers will be better at supporting
their latest version as opposed to older offerings. A final reason
to upgrade is to incorporate patches and fixes.
Backward compatibility is a key factor in the cost versus benefit decision to upgrade the HMI software version. If the current HMI software supplier does not provide a smooth migration
path, it may be an opportunity to switch to another supplier
that does, since it can reduce engineering investment for future
upgrades (see Table 2).
Its good practice to check the HMI software suppliers
release notes for newer versions. Look for potential issues that
have been solved and find new features. New features may
enable implementation of new functionality, such as support for
multi-touch and gestures.
A machine or process retrofit may involve the HMI and the
controllers as well. In many cases, new controllers support tagbased communication rather than just memory addresses. In this
case, upgrading the HMI to a version that supports tag integration with the controller will considerably reduce the time needed to adjust the application. It will also minimize configuration
errors since the tags will be browsed and selected from the controller, instead of typing them manually.
Newer versions of HMI software often include support for
Table 2: Considerations when

migrating to new versions of HMI software
n Backward compatibility
n Incorporating new features and graphics
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n Tag integration
n Traceability and authentication
n New built-in drivers to replace older custom
communication drivers
n Connectivity
n Security
n Remote access
P2
inside process
importance and necessity of cyber security in

automation systems. There is no silver bullet to
prevent or mitigate cyber attacks, but keeping the
latest version of the HMI software updated is an
effective way to minimize or eliminate vulnerabilities from previous versions.
Changing from one supplier to another
Figure 2: New HMI software, such as InduSoft

Web Studio, can pay
for itself with features
such as remote access,
tag integration, and
improved cyber security.
trace ability and authentication, features that can ease compliance with
regulations and also improve operations.
New software versions improve
communication
Connectivity or interoperability is a key factor

in modern systems. New HMI versions may provide additional tools to exchange data with new
devicesbut also with ERP systems, databases,
historians, cloud-based systems, and others.
Many HMI software products were originally
designed to display information only on the PC
or other device where they are installed and running. However, most new products allow remote
maintenance, troubleshooting, or even visualization of the application. This remote access, from a
PC, tablet, or smartphone, improves productivity
while minimizing downtime.
The integration of cloud-based systems and
wide area networks connecting geographically
dispersed systems and Internet of Things (IoT)
architectures have substantially increased the
Table 3: Considerations when changing

HMI software suppliers
n Import tools
n Tag, ignore, import, replace, etc.
n Screen graphics
n Security
n Communication configuration
n Alarms
n Recipes
P4
Some of the PC-based HMI software packages can import existing applications from installed
PC-based HMIs, even those made by other suppliers, and can also include tag integration for a variety of drivers, making it easy to import HMI tags
directly (see Table 3). Using these import tools
can make it much easier to switch from one supplier to another, with the end result being a better HMI with improved capabilities (see Figure 2).
Import tools can greatly reduce the cost to
migrate HMI applications to different HMI software platforms that may offer better value or performance. Import tools automatically import tags
from legacy systems and can even support merging legacy applications with existing ones.
When migrating applications from HMI products not supported by native import tools, its
often possible to copy the list of tags from an
external list, in Microsoft Excel for example, and
paste it into the application tags sheet. Import wizards can also import screen graphical components
such as objects and pictures, along with their related properties and animations.
Security settings are typically not imported automatically for two main reasons. One is to
respect the confidentiality of authentication settings, primarily passwords. The second is the differences between revisions or different systems.
The new upgraded software and related security
system is likely to be substantially more sophisticated, and it also may use different configurations
than legacy systems. Therefore, configuring the
security settings of imported applications through
the graphical user interface (GUI) of the end product is recommended.
Communication settings for supported protocols should be automatically imported. This is possible in HMI applications with separation between
the tags database and communication drivers,
which also facilitates replacement of a legacy driver and protocol configuration with a new one.
Alarm conditions and messages should also be
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The support for recipe data depends on the
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The HMI upgrade decision
maintenance, troubleshooting,
The decision to upgrade HMI software, or

any other system for that matter, should be made
on a cost-benefit analysis. Any system, whether hardware or software, will eventually become
obsolete. As obsolescence approaches, downtime
and safety risks increase.
In other cases, even before an HMI software
platform becomes obsolete, a new system can
provide substantial benefits that justify the cost
involved in the upgrade. Although migrating to a
different supplier rather than to a newer version
from an existing supplier may invoke higher cost
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lower costs in the long run. Switching to an HMI
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openness, interoperability, support for standards,
and reduced maintenance costs can make a change
worth considering.
Some hardware manufacturers design proprietary software that can lock users into their HMI
hardware, controllers, and networks. On the other
hand, HMI software from hardware-agnostic sup-
Go Online
For more info, see this article

online and the Control Engineering HMI page,
www.controleng.com/hmi
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- Fabio Terezinho is director of consulting services at InduSoft and product manager at Wonderware by Schneider Electric. Edited by Peter
Welander, Control Engineering contributing content specialist, pwelander@cfemedia.com.
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inside process
A better way to
install automation
in classified areas
Instead of employing protection methods, its
often better to move automation systems to less
hazardous areas and to use components rated
for use in these locations.
Key
concepts
Automation equipment
used in hazardous areas
requires special protection
to prevent fires and explosions.
Protective measures
necessary can be expensive or problematic.
Locating equipment
outside of the most strictly
regulated areas can be far
simpler.
lassified areas are often found in industrial plants due to the presence of
hazardous gases and dust. When automation components are installed in
these areas, certain rules, regulations, and design
standards must be followed to ensure safety.
Hazardous areas are classified according to
either National Electrical Code (NEC) or the
International Electrotechnical Commission (IEC).
Table 1 shows a simplified version of this classification system, and much greater detail can be
found within the detailed regulations, specifically
NEC Article 500 and IEC 60079.
Using the NEC standards for reference, Table
1 shows that Division 1 is more hazardous than
Division 2 because hazards are more likely to
be present. Therefore, automation components
Figure 1: Explosion-proof enclosures are much heavier and more

expensive than their nonrated counterparts and typically require periodic inspections to ensure integrity. Courtesy: Vynckier
P8
installed in Division 1 require a higher level of

protection than those installed in Division 2.
Three main methods are used to implement
levels of protection as required in classified areas:
explosion proof, purging, and intrinsic safety.
All these methods of protection require careful
designand often expensive components, installation, and maintenance.
Examining these three protection methods
provides context for an alternative way to install
automation components in classified areas.
Explosion-proof approaches
Explosion-proof enclosures and conduit systems protect automation components in hazardous

areas through two methods. First, they are sealed
to limit the amount of gas or dust that can enter
the enclosure or conduit system. Second, they
must have the structural integrity to contain an
explosion so it doesnt propagate throughout the
classified area. These enclosures are typically used
in Division 1 areas.
Protection with enclosures has been used for
many decades and is well understood by many
engineers, designers, and plant maintenance personnel. Many suppliers provide explosion-proof
enclosures and conduit systems, and the design
standards for such systems are readily available.
But compared to the standard National Electrical
Manufacturers Association (NEMA) 4 enclosures,
explosion-proof enclosures are very expensive, quite
large, and very heavy (see Figure 1). Because these
enclosures are sealed, the only practical method to
dissipate heat is through the enclosure itself, limiting the type of components the enclosure can
house, or requiring the enclosure to be oversized
which further adds to costs.
Any operator interface components must be
rated for use in the area, which precludes the use
of any type of graphical interface in a Division 1
area. Graphical interfaces can be mounted inside
the enclosure and viewed through a window, but
this limits visibility.
Great care must be taken during installation
of the enclosures and conduit systems to ensure
proper sealing is preserved, and conduits must
often be potted at transitions from Division 1 to
Division 2 areas. Hot-work permits and accompanying precautionary measures are required to open
explosion-proof enclosures, making servicing of
the components inside the enclosure very expensive and difficult.
Regular inspections of explosion-proof enclosures and conduit systems are required in some
classified areas and strongly recommended in others. Inspections verify the integrity of the sealing
systems and reveal the need for maintenance.
Figure 2: Purging enclosures with air or an inert gas can allow nonrated components to be used in hazardous areas, although the supply of air or gas has to be
maintained constantly. Courtesy: Pepperl+Fuchs
next often require IS barriers, adding to

the complexity of these systems.
Avoid the hazard
As explained, all three of the leading protection methods require detailed

design and often considerable expense
for system purchase and installation.

The expense doesnt stop with installation, because IEC 60079 requires initial inspections of components installed
in classified areas and ongoing periodic
inspections, typically done annually. The
inspections often reveal areas requiring
Purging problems
Another method for installing automation components in hazardous areas

is to purge enclosures with compressed
air or an inert gas. Purge systems dont
allow hazardous gases or dusts to enter an
enclosure because the interior is always
under positive pressure.
Depending on the type of purge system, this method allows standard enclosures and unrated automation components
to be used in Division 1 and Division 2
areas. But purge systems can be quite
expensive, particularly when they are
used in Division 1 areas (see Figure 2).
The cost doesnt stop with installation,
as purge systems require a constant supply of compressed air or an inert gas. This
approach makes maintenance of the components within the enclosure problematic
because the enclosure cannot be opened
during normal operation.
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Limitations of IS options
Intrinsically safe (IS) systems can be

safely installed in Division 1 and 2 hazardous areas because the components and
wiring systems cannot release sufficient
energy to ignite gas or dust in the area.
Unlike explosion-proof or purge systems, this method of protection permits
many types of maintenance during normal operation.
Because each component must be
rated for use in the area, the range of
items available for use is limited. Many
common automation components, such as
programmable logic controllers (PLCs)
and motor drives, arent available with
an IS rating. Even when IS-rated components are available, there is often an
added charge from the supplier.
The design of IS systems requires a
high level of engineering expertise, adding to implementation time and expense.
Transitions from one classified area to the
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inside process
maintenance, further adding to expense.
Realizing this, many suppliers began to introduce components within the past few years which
can be safely installed and operated in Class 1,
Division 2 (or Class I, Zone 1) classified areas.
There is a significant difference between those
two divisions even though they are in the same
class, and the requirements for applicable devices
and components also are significant.
Location, location, location
Like real estate, when it comes to hazards, its

all about location. Often the best approach for
dealing with hazardous locations is staying out of
them. Install as much of the automation equipment
as possible outside of Class 1, Division 1 areas.
Even moving to a Division 2 area makes a major
difference. This isnt as difficult as it may sound.
In many industrial plants and facilities, relatively
Table 1: NEC Divisions and IEC Zones

Frequency of Hazard Occurrence
NEC Classification
IEC Classification
Continuous hazard
Division 1
Zone 0
Intermittent or periodic hazard
Division 1
Zone 1
Abnormal condition hazard
Division 2
Zone 2
Table courtesy: Hoffman
few areas are classified as Division 1, and these

areas are often quite small. Even when they have
a large footprint, improvements can often be made
to limit the amount of gases released to the atmosphere, thus reducing the footprint of areas classified as Division 1.
Once Division 1 areas are reduced to a practical minimum, then all new automation components should be located in an adjacent Division 2,
or even better, in unclassified areas unless theres a
compelling reason to do otherwise. In some cases,
it may make sense to relocate existing automation
components from Division 1 to Division 2 areas
to avoid the related inspections and maintenance.
For those few automation components that
must be located in Division 1 areas, its often possible to use IS-rated components and connect to
those components from Division 2 areas by way
of IS barriers. Once all Division 1 areas have been
minimized, and Division 2 and unclassified areas
consequently increased, careful automation component selection can be made to use only those
items rated for use in Division 2.
Component selection and application
As recently as 20 years ago, there were very

few automation components rated for use in Class
Table 2: Automation components

rated for use in Division 2
n Operator interface devices
n PLCs and other controllers
n I/O devices
n Smart relays
n Interface relays
n HMIs
n Variable frequency drives (VFDs) rated
up to 100 hp
n Pushbuttons
n Pilot lights
n Selector switches
n Power supplies
n LED flood lamps
I, Division 2 areasand many of these were related to PLCs and relays. This situation has changed
dramatically in the past few years, as the automation components listed in Table 2 indicate. And
the list is steadily growing as suppliers respond to
end-user demand.
If a component is rated for use in Division 2, it
can be installed in a standard enclosure and safe-
ly used without requiring any

additional protection. Due to the wide
availability of rated components, its now possible to assemble a complete control system with a
human-machine interface (HMI), a PLC, an input/
output (I/O) device, a power supply, motor drives,
and other required componentsall rated for
Class I, Division 2 use.
This approach requires much less detailed
design than the three main protection methods and
costs less. No initial or periodic inspections are
required, and maintenance is greatly reduced.
When automation components suitable for
Division 2 use were first introduced, they often
carried a substantial price premium over nonrated counterparts. But this price premium has been
greatly reduced in recent years, often eliminated
completely (see Figure 3).
Figure 3: Many automation

components are now available with Class I, Division
2 ratings at little or no extra
cost. Courtesy: Idec
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inside process
In many cases the product parts and
materials have not been changed, just
the inspection requirements for compliance. For example, in the case of an
electromechanical switching compartment, the spark-producing components
must be plastic sealed. The Division 2
rating assures that the sealed compartment will not leak over the components
life. As a result, there is now a wide
variety of electromechanical and solid-state relays rated for use in Class I,
Division 2 areas.
As LED lighting has become commonplace, new Class I, Division 1 and
2 lamps have become available and
often are retrofitted in oil refineries and
other facilities as they modernize lighting systems.
Typical applications for automation
components in Class I, Division 2 areas
include but arent limited to:
n Upstream oil and gas facilities for
exploration and production
n Midstream oil and gas pipelines and
storage facilities
n Oil refineries
n Petrochemical plants
n Paint booths and paint mixing
facilities
n Water and wastewater treatment
plants
n Mining facilities
n Pharmaceutical plants
n Agriculture facilities such as grain
silos
n Food processing plants.
Protection vs. location
The three main methods for protecting

automation components installed in classified areas are explosion-proof enclosures, purged enclosures, and intrinsically
safe systems. Depending on the specific application and automation components, each method can be effective. But
each entails considerable upfront cost and
ongoing care, service, and maintenance.
A viable alternative in many cases is
to install automation components and
systems in Division 2 instead of Division 1 areas and to then use components
rated for Division 2 use. This simplifies
design, cuts costs, and reduces operating

and maintenance expenses.
In response to user demands, suppliers have introduced many automation components suitable for use in
hazardous areas, with more becoming
available regularly. With careful components selection, most types of automation systems can be safely installed
in Division 2 areas. ce
- Steve Massie is a product manager
responsible for relays, lighting, circuit
breakers, terminal blocks, and hazardous location products for Idec. Edited
by Peter Welander, Control Engineering contributing content specialist,
pwelander@cfemedia.com.
Go Online
For references and more, see this article online
and the Control Engineering Process Safety page
under the Process Manufacturing tab at:
www.controleng.com.
Standards organizations:
www.necconnect.org
www.iec.ch
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back to
BASICS
WLAN design basics, considerations

Rational planning and design, based on a thorough preliminary evaluation, can ensure
that a wireless network will work the first time and easily expand without disruption.
Key
concepts
Wireless is an unbounded medium, and the system design must facilitate
efficient wireless signal
propagation.
Use rational planning
and design to ensure that
a WLAN will work and
expand reliably.
WLAN design considerations include capacity,
access points, and facility
type.
Consider this...
When designing a WLAN,
what is the one aspect you
consider to be most crucial
to its success?
64
eing an unbounded medium, wireless

system design must facilitate efficient
propagation of radio frequency (RF,
wireless) signals. This facilitates coverage and capacity, which are primary wireless
local area network (WLAN) parameters. Where
does the RF energy reach and how many clients
can use it effectively before it becomes over utilized and slow? Rational planning and design,
based on a thorough preliminary evaluation,
can ensure that a WLAN will work the first time
and allow ease of expansion without disruption.
A well-designed WLAN will provide years of
reliable service, and the return on investment
(ROI) will be realized more quickly.
For WLAN RF propagation, different types
of antenna systems can shape the RF beam to
service specific areas and exclude others also can
modify coverage. In most cases, an access point
(AP) will use an omnidirectional antenna theoretically propagating in all directions. For this discussion, assume this to be a circle with a 200-ft
diameter line of sight at an output of 100 mW (20
dBm). This means that client devices within 100-ft
of the AP will receive a good signal (> -80 dBm).
Obstructions create signal attenuation depending
on materials. Plywood and drywall do not present
much attenuation, while concrete and steel greatly
attenuate RF. So does the human body, which is
made of more than 60% water. Groups of people
can create more attenuation as an elevator shaft
made of reinforced concrete.
An AP cannot be placed in a convenient location and be expected to provide seamless and
error-free network connectivity. The facility must
be evaluated for wireless LAN suitability. This is
called a survey and can be either a virtual survey,
a predictive survey, or an on-site, physical survey. A survey can determine:
Presence of neighboring WLANs and other
sources of RF that could interfere
Propagation pattern(s) of proposed AP(s)
required to provide desired coverage
Effect on propagation due to attenuation by
walls and other architectural features
Effect on propagation due to reflections
and other behavior
Location and type of wired network infrastructure (wiring closets, copper vs. fiber).
Capacity is a primary issue to consider. Capac-
ity is not bandwidth or throughput, but the ability

of the WLAN to provide reliable and available
connectivity to clients in the coverage area. If a
given client is served by four APs and everyone is
out to lunch, plenty of bandwidth and throughput
are available. What if the network becomes unusable when everyone returns and uses the network?
Contention, transaction time
As more clients use the AP, there is increased

contention for the medium. This requires more
transaction time and can result in re-transmissions
due to collisions. Only one client can be associated
to an AP at a time. The transaction may last only a
few milliseconds, and other clients are contending
for AP use. Wait times and re-transmissions go up
in proportion to the number of clients.
Capacity cannot be accurately calculated in a
predictive survey. Sophisticated algorithms will
take contention into account, but nothing can predict how people or devices will use the network
in real time; mobility of devices complicates
this prediction. When a device is mobile, it can
roam from one coverage area to another, creating increased contention on the new AP. Quality
of service (QoS) algorithms and secure roaming
will preempt lower priority traffic on the new AP
and could cause further congestion. Mobile clients traveling to the extremes of the coverage area
could also experience a loss of contact with other
clients, resulting in collisions. All clients listen to
all transmissionsif only the AP hears a client,
then other clients will assume the medium is free.
Adding more APs and operating them at lower
power output usually can solve the capacity problem. Another technique essential for proper function of WLAN operation and device roaming
is using multiple channels for the several APs
installed in the facility. See more online. ce
- Daniel E. Capano, owner and president, Diversified Technical Services Inc. of Stamford, Conn., is
a certified wireless network administrator (CWNA).
Edited by Chris Vavra, production editor, CFE
Media, Control Engineering, cvavra@cfemedia.com.
Go Online
www.controleng.com/blogs has more on this Capano wireless
tutorial, including details about adding more APs and multiple
channel use. Control Engineering has a wireless page.
www.controleng.com/networking-security/wireless
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