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 JANUARY 2016

Vol. 63
Number 1

Features
18 More intelligent and efficient
PLC programming
Cover story: IEC 61131-3 Programming Languages: Whats the
COVER: Control Engineering research with AutomationDirect suggests that
18
programming diversity and attention to standards might add efficiency. Photo
acceptance rate of this control programming standard? Ladder courtesy: Facts Engineering, AutomationDirect

diagrams remain the simplest and most popular approach for PLC
programming but may not be the most efficient way. Lack of
interoperability may be a problem.

22 IT helps in the evolution of controls

Cover story: As IT and operational technology (OT) data converge,
so do the physical departments, which has some major implications for
the controls department.

24 Data historians deliver value

from big data in the cloud
Data historians help manufacturers collect, store, and retrieve process
data in cloud-based applications, comparative analysis, and quality
improvement in the Industrial Internet of Things (IIoT).
24
25 Big data and cloud for manufacturing
Industrial Internet of Things (IIoT),Industrie 4.0 applications, and
basic electronic services are moving from local servers into the cloud,
using Internet-based software as a service (SaaS).

26 Baselining, trending machine data 29

Cloud: Using applications of the Industrial Internet of Things (IIoT),
plant managers can collect and analyze equipment life-cycle data
to weed out flaws and failures.

29 Overcoming flow measurement challenges

Matching the flowmeter to the application can help engineers
overcome flow measurement issues. Know when to use which
technology.
33 System integrators plan, evolve for the future
Get tips on recruiting and retaining young talent to overcome the
skilled worker shortage from CFE Medias interviews of three repre-
sentatives from the 2016 System Integrators of the Year. See video.
45 Hannover Messe Preview
Hannover Messe is a big event for a small U.S. manufacturer.
AirSquared officials found value in expanding their global brand by at-
tending Hannover Fair. Read first-hand advice on how to derive value.
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 63, No. 1, GST #123397457) is pub-
lished 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 2016 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
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TROL 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, regard-
less of whether such errors result from negligence, accident or any other cause whatsoever.

2 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com



input #3 at www.controleng.com/information
Re-Route Your Temperature Measurements
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 JANUARY 2016

Vol. 63
Number 1

Inside Process
Appears after page 34; If not, see the Digital Edition:
www.controleng.com/DigitalEdition
P1
P1 Applying heat exchanger
control strategies P7
Integrating control schemes, such as feedback, cascade, and
feed forward techniques, can satisfy the control requirements
of even highly challenging heat exchanger temperature control
applications.

P7 When moisture matters

Learn why moisture content can affect the quality and cost of
the final product and how a near infrared (NIR) moisture meter
can help.

Departments Products
8 Think Again 61 Electro-hydraulic valve
Most-read Control Engineering articles of 2015 actuators for oil and gas opera-
tions; Camera series designed
10 Apps for Engineers for medical, food and beverage
applications; Generation heat
Mechanical and measurement
exchanger with proprietary
technologies; Multi-touch
16 Research
HMI for SCADA, MES
Cyber security
applications; Turbine flow
meter series for oil and
17 Control Engineering International
gas, chemical applications
Changing from made to created in China

64 Back to Basics
Open standard wireless systems
62 Software for CAD assemblies and mechanical
News designs; EtherCAT I/O controller for automation systems;
Electromechanical cylinder for applications with frequent
cleaning cycles
12 School celebrates 10 years of success enrolling women in
engineering studies; Software company acquired

13 Groups collaborate for transparent industrial network

structure; Industry forum event to focus on IIoT,
information technology trends

14 Events, online news, corrections

www.controleng.com CONTROL ENGINEERING JANUARY 2016 | 5

 More resources posted daily at:
JANUARY
www.controleng.com

Trending New Products Control Systems Process Manufacturing Discrete Manufacturing System Integration Networking & Security Info Management Education & Training

At a time of
Calling all integrators
transformation,
CSIA helps Create your
members thrive system integrator
SI companies will have to corporate profile
adapt to the new realities of Your profile will be available
higher IT content, an increas- to more than 60,000 end users
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Integrators of the Year. more here:
www.controleng.com/global-si-database
 Matrix Technologies, Maumee, Ohio
 Concept Systems, Albany, Ore.
Oil & Gas Engineering
 ECS Solutions Inc., Evansville, Ind. December issue
Oil & Gas Engineering
provides industry-
NEW: Two new newsletters for 2016 cover automation planning and design,
specific solutions
and industrial networking. Subscribe to Control Engineering newsletters at
designed to maximize
www.controleng.com/newsletters. uptime and increase
productivity through the
use of industry best prac-
NEWSLETTER: SYSTEM INTEGRATION tices and new innova-

Developments in tions, increase efficiency

from the wellhead to the
wireless communication refinery by implementing automation

for industrial use and monitoring strategies, and maintain

and improve safety for workers and the
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 Practical considerations for selecting an
tion at www.oilandgaseng.com
industrial wireless sensor network
 Water, raw aluminum produce steam,
hydrogen, alumina Read this on your tablet
 CAN FD: From theory to practice The tablet and digital
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Watch a video that explains key facturers can use stra-
trends, including engineering
e?

tegic IoT solutions and

niz
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tai
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for

retention
21
u
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information flow within

Se
n
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he
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Si
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plant-based SCADA sys-

W

www.controleng.com
ar
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The System Integrators of the Year combine 2016-Modernization Cov Bug.indd 1 12/15/15 10:43 AM

tems. Also link to online extra articles.

technology with a customer-centric approach.
www.controleng.com/digitaledition
See roundtable video discussion. See also, p. 33.

6 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com

 Reliable Detection
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input #5 at www.controleng.com/information
THINK AGAIN article rankings
Top articles of 2015
Salary survey and career advice, variable frequency drive help,
process control tutorials, and help with PLCs and DCSs are among
the top 10 articles of 2015. Online, also see two top-20 rankings.
M
Most-read 2015 articles from
Control Engineering subscribers and other
www.controleng.com visitors include the sal-
ary and career survey, variable frequency
drive myths, process control tutorials, and
what control engineers should know about
management, among others. Articles reflect
similar issues and topics as in 2014 although
salary and career survey moved from eighth
to first, from 2014 to 2015, perhaps reflecting
greater concern about the lead issue in both
surveys, shortages of skilled workers. Think
again: this isnt just another best of list;
these stories matter most for those interested
in advancing in professions that use controls,
automation, and instrumentation.
1. Control Engineering salary and career
survey, 2015May 18: Research shows slight-
ly less is expected for salary and significant-
ly more for bonuses compared to 2014, the
skilled worker shortage remained highest on
the list of challenges.
2. The truth about five common VFD
mythsAug. 8: Knowing the truth about VFD
operation can simplify the selection process
for choosing a variable frequency drive.
3. A dual split-range control strategy for
pressure and flow processesApril 6: Main-
taining setpoint for two-mode or wide-range
operations can be much easier with two con-
trol devices. Split-range control has been
widely used in industrial processes for con-
trolling pressure, temperature, and flow.
4. Feed forwards augment PID control
March 31: Feed forward estimates the output
from a proportional-integral-derivative (PID)
control algorithm without waiting for the PID
MORE
ADVICE
Articles dated later get greater accolades, with less
time to accumulate clicks.
Go online
In the 11-20 ranking topics include artificial intel-
ligence, control panel standards, and cyber security.
Another 1-20 ranking includes articles on cascade
control, open- vs. closed-loop control, and the defini-
tion of medium voltage.
8 | JANUARY 2016 CONTROL ENGINEERING
algorithm to respond. It reduces the error
faster or keeps the error smaller than relying
on the PID algorithm alone.
5. Selecting and applying VFDsFeb.
2: Clear understanding of the application,
noise sources, and configuration parameters
ensures peak variable frequency drive (VFD)
performance, efficiency, and reliability.
6. Seven things control engineers should
know about managementposted Dec. 24,
2014, but appeared in the January 2015 issue:
Engineers should know 7 things about man-
agement and communication to accelerate 630-571-4070, x2203; JLanghenry@CFEMedia.com
their careers.
7. Six steps to choose between PLC
and DCS for process industriesOct. 29:
Learn how to choose between PLC and DCS.
Though PLC and DCS technologies were
invented to serve different industrial pro-
cesses, the past 15 years have seen a merger of
functionalities between both worlds.
8. High-performance HMIs: Designs to
improve operator effectivenessJan. 14: Users
and system designers consider how changing
HMI strategy can help make operators better
at their jobs.
9. Support-focused enterprise controls:
PLC BasicsMay 19: PLC programs do not
behave like scripted language programs
used by most computer applications. A basic
understanding of control application funda-
mentals is crucial for designing an effective
support-focused system.
10. Overcoming process deadtime with
a Smith Predictor Feb. 17: A controller
equipped with an accurate process model can
ignore deadtime. Deadtime generally occurs
when material is transported from the actua-
tor site to the sensor measurement location.
Until the material reaches the sensor, the sen-
sor cannot measure changes. ce
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APPS FOR ENGINEERS data collection
www.controleng.com/appsforengineers
Mobile apps for measurement
Mechanical and measurement mobile applications
have potential to help engineers do their jobs bet-
ter. CFE Medias Apps for Engineers is an interac-
tive directory of engineering-related applications
for Apple iOS and Android operating systems from
various companies. Apps are organized by catego-
ry, company, and type. These are listed in the app
as of December 2015.
Converter
iOS 6.0 +, Android 2.2
Cost: Free
Company: Trelleborg
Website: www.trelleborg.com
This app converts frequently used units and currencies in an efficient and con-
venient way. It comes with a hardness converter based on ISO and ASTM Stan-
dards to convert between popular hardness scales for various material types.
Some features include easy-to-use interface; currency converter with in-app
exchange rate update functionality; more than 250 engineering and scientific
units in 22 categories; hardness converter with 16 conversion tables based on
ASTM E140-07 and ISO-18265 for quick conversion between scales.
NI cDAQ-9191 Data Display
iOS 5.0+, Android 2.1+
Cost: Free
Company: National Instruments
Website: www.ni.com
The NI cDAQ-9191 is a 1-slot NI CompactDAQ chassis with Wi-Fi communi-
cation combined with an NI C Series measurement module to create a small,
portable data acquisition device. Choose simulated device to evaluate the app
without actual hardware; automatically discover devices on a local subnet; ac-
quire continuously or a certain number; pinch the graph to zoom in on a signal;
and email a graph and data.
Turbo Tool
iOS 6.0+, Android 2.3.3+
Cost: Free
Company: Danfoss
Website: www.danfoss.com
This app makes it easy for field service technicians to troubleshoot Danfoss
Turbocor compressor issues on-site with instant access to troubleshooting data
and quick reference charts. Field service technicians can use it to identify symp-
toms, work through the possible causes, and find remedies through suggested
required actions.
Mechanical Engineering
iOS 4.3+
Cost: $5.99
Company: MultiEducator
Website: www.multieducator.net
The app contains more than 300 important mechanical engineering formulas,
conversion formulas, as well as 70 area formulas. Major areas covered include:
actuators bearings, belts, boiler, brakes, clutches, elevators, gears, fluid power,
heat transfer, internal combustion, kinetic energy, metalworking, plates, plumbs,
power plants, refrigeration, shafts springs, and vehicle drive.
10 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com
 More resources posted daily at:

www.controleng.com

digital edition
Exclusives, Online Extras: Benefits of the Control Engineering Digital Edition include
tablet-friendly viewing (HTML5), exclusive content in every issue; headlines link to the
longer version posted online; links are live where a URL is provided; and an email link
arrives when ready. In addition, link to additional Online Extra articles.

DIGITAL EDITION EXCLUSIVES

DE1 Eight ways medical device manufacturers
can use strategic IoT solutions
Developments in monitoring power and performance data allow
manufacturers to provide better service and preventive
maintenance packages.

DE5 Journey to the center of the plant:

SCADA systems information flow
Understanding the network communication process between a PLC
and the SCADA computer is important to streamline the process.

ONLINE EXTRAS (Click on the headlines or search www.controleng.com.)

Researchers developing method to make

microelectromechanical systems cheaper
Researchers at MIT have been working on making microelectromechanical systems (MEMS) cheaper
by developing a fabrication device that sidesteps many of the requirements that make conventional
manufacturing expensive.

Engineering ethics and software concerns

Virtual machines can solve many problems while keeping operations flowing smoothly, but when companies
are duplicating software via virtual machines, this brings up some ethical issues that need to be addressed.

Accelerating innovation in the pharmaceutical industry

The key to success in the pharmaceutical industry is innovation.

Workplace trends demand greater depth and breadth of skills

Success in todays workplace calls for expanded capabilities, from demonstrating technical expertise to
meeting with clients, or working with teams across disciplines, companies, and countries. The implications
are vast, particularly for millennials.

Industrial GFCIs help meet OSHA grounding requirements

New technology developments help address maintenance requirements for an assured equipment grounding
conductor program.

Five tips for automating your food processing plant

To optimize ROI, its important to learn which areas of your food processing facility are best suited for
automation. Consider these five tips for improving your plants automation capabilities.

www.controleng.com CONTROL ENGINEERING JANUARY 2016 | 11

 DIGITAL EDITION exclusives
8 medical device manufacturers
can use strategic IoT solutions
Developments in monitoring power and performance data allow manufacturers to provide better
service and preventive maintenance packages. Learn about the eight ways the Internet of Things
(IoT) is transforming the way medical equipment manufacturers do business.
MORE
ADVICE
KEY CONCEPTS
Medical equipment manufacturers
have a lot to gain by incorporating the
IoT into sales, customer service, and
product support strategies.
The IoT will help medical device
manufacturers improve operational
efficiency, gain big data insights, and
improve new device production.
Manufacturers will benefit and
succeed if they take advantage of
the IoT and the changing business
environment.
GO ONLINE
See more stories on the Industrial
Internet of Things (IIoT) at
www.controleng.com.
CONSIDER THIS
How else could the IoT benefit medi-
cal device manufacturers?
DE1 | JANUARY 2016
ways
T
he health care landscape is changing
fast, and many medical device orga-
nizations are seeking ways to make
improvements amidst the evolution.
In an industry where knowing is half
the battle, medical equipment manufacturers
have a lot to gain by incorporating the Internet
of Things (IoT) into their sales, customer ser-
vice, and product support strategies.
With new technologies and competitive pres-
sures to consider, manufacturers are forced to
ask some serious questions about the future of
their business: How will IoT shape how manu-
facturers engage with equipment after-market?
How will increasing customer demands affect
how medical equipment manufacturers produce
and service new devices?
How medical device
manufacturers benefit from IoT
The IoT is producing volumes of machine
data that businesses have never had access to
before. For manufacturers, all of this addi-
tional equipment information opens a range
of sales, consulting, service, and development
possibilities.
Here are some of the ways medtech manu-
facturers will benefit from improved efficiency,
productivity, cost savings, and revenue thanks
to connected equipment and the tools to make
sense of incoming data from that equipment:
CONTROL ENGINEERING
1. Increase first-time fix rates
and grow service margins
With greater insight into equipment per-
formance, service technicians will be more
prepared to resolve issues before they arise.
Manufacturers can set parameters on connect-
ed equipment that trigger an alert to the service
organization when the machine is perform-
ing outside set parameters. With the right sys-
tem to interpret what the machine is saying,
this alert can relay equipment performance and
repair history, customer information, warran-
ty details, and other information the technician
needs to do the job well the first time. Eventu-
ally, as machines become more computer-like
and driven by software, service teams wont even
have to make a trip to the customer site to fix an
issue. Theyll be able to diagnose and repair the
machine remotely.
2. Improve customers
operational efficiency
One surefire way to get on a health care cus-
tomers good side: make their daily operations
more efficient. For example, embedding IoT
sensors in parts and devices is a method that
can help health care providers improve opera-
tional efficiency. Another example is improv-
ing medical inventory stocking efficiency. Many
hospitals overstock certain inventories to pre-
vent running out during an emergency. Because
www.controleng.com
of that, supplies can go unused or expire. By
implementing solutions such as radio frequen-
cy identification (RFID) and mobile scanners
connected with cloud technology, hospitals
gain real-time inventory numbers and status
to ensure they have what they need, where they
need it, and when they need it.
3. Reduce equipment costs by
leveraging predictive maintenance
With access to machine details in real time,
service providers will increase machine avail-
ability and uptime because preventive IoT data
makes field service actionable. In other words,
with continuous data monitoring of equip-
ment in the field, manufacturers can make ser-
vice activities proactive rather than reactive by
making sure they respond to alerts and resolve
machine issues before a device failure occurs.
IoT sensors in equipment activate a work order
automatically when a part isnt working right.
As the work order is generated, the system
orders parts and schedules a preliminary ser-
vice call. When the parts arrive, a ser-
vice truck is dispatched to the site to
perform the PM. Each of these steps is
done automatically in seconds since no
human interaction is required.
4. Connect devices and
optimize patient outcomes
with big data
By connecting equipment through
the IoT, manufacturers are able to stay
connected to their machines and cus-
tomers. As these technologies evolve and IT
infrastructures improve, so will the number of
medical devices that are linked to them, mak-
ing them smarter and better at optimizing
treatment, said Qmed in their coverage of big
data in the medical device space. The demand
for big data will cause many equipment manu-
facturers to make use of IoT strategies in order
to stay relevant.
5. Provide additional insight and
advice for equipment end users
Data from connected equipment allows device
manufacturers to offer detailed advice to equip-
ment end users. With this additional machine
information to support their suggestions, manu-
facturers can function more like trusted equip-
ment consultants and sell that consulting time
and value as part of a service package. In a con-
nected world, strong service offerings are more
important than ever. IoT allows manufacturers
www.controleng.com
to offer additional services that go along with the
product when they sell it.
6. Sell a system of devices and
services rather than individually
Integrating smart, connected equipment
enables better overall equipment performance.
According to one example from Deloitte Uni-
versity Press: Getting electrocardiograms
done outside of the hospital ... long required
using portable machines with price tags over
$1,000, but recently, patients ... have been able
to buy individual devices for as little as $75.
Subscriptions to cardiac monitoring services
leverage this lower cost collection of data by
enabling more timely interventions in case of
a cardiac event. In other words, we can often
expand one technologys created value by
embedding it in a more inclusive ecosystem.
Manufacturers can now offer a package of
connected equipment and related services that
optimize overall results. Smart, connected
equipment is shifting the original equipment
Real-time information access ensures
theres opportunity to respond to alerts
and resolve machine issues before a
device failure occurs.
manufacturer (OEM) business model to selling
a system of products, sensors, and data to help
machine users become more efficient.
7. Ensure machines are used equally
Keeping equipment running is the major
priority in the health care industry. One way
for end users to prevent unnecessary spending
on new machines is to prioritize service and
make use of usage data by connecting equip-
ment through the Internet. IoT sensors reveal
how long, how often, and how well machines
are being used. This means that if one piece
of equipment is continually overused, while
another is rarely placed in the rotation, hos-
pitals can make adjustments so they receive
equal wear. In addition, service organizations
can advise their health care customers when
the best equipment scheduling times are by
using a cloud-based software, such as a sched-
uling management tool.
CONTROL ENGINEERING JANUARY 2016 | DE2
 DIGITAL EDITION exclusives
8. Inform (and improve) the
production of new devices
In addition to improving service programs
and patients ability to use devices more effi-
ciently, IoT data can inform manufacturers about
equipment performance to guide engineering,
product, and quality improvement input. By
Smarter designs: If a particular device
uses resources too quickly, the manufacturer
has the information needed to change the
design in its next iteration.
continually monitoring equipment performance,
manufacturers can fine-tune how to differenti-
ate their products, making them more produc-
tive and useful for the end user. For example, if
a particular device tends to use resources too
quickly, the manufacturer can change the design
in its next iteration.
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magazine as a digital publication?
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our digital edition, on a more
interactive and user-friendly platform,
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Update now at www.controleng.com
Strategic IoT plan for services
Smart, connected equipment and new prod-
uct capabilities introduce tremendous advantages
for medical device manufacturers incorporating a
strategic IoT plan into their service solution. Not
only do they experience reduced costs to main-
tain and support medical equipment, theyre also
able to increase equipment uptime and offer cus-
tomers high levels of product support.
The health care industry is headed toward a
more transparent, connected environment.
Both patients and health care providers stand
to gain from continuous access to increasingly
connected devices, and theyll be willing to pay
for it.
By keeping equipment functioning and pro-
viding the data that allows end users to monitor
things like patient health, manufacturers stand
to see huge benefits if theyre ready to adapt to
the changing business environment and new
technologies to help them succeed. ce
Joanna Rotter is content marketing manager at
MSI Data. MSI Data is a CFE Media content
partner. Edited by Chris Vavra, production edi-
tor, Control Engineering, cvavra@cfemedia.com.
Engineering is personal.
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 DIGITAL EDITION exclusives

Journey to the center of the plant:

SCADA systems
information flow
Understanding the network communication process between a PLC and the SCADA computer
is important because there are a number of elements that need to be addressed, such as the
language a computer speaks and the tools needed to streamline the process. This article is part
of the Journey to the center of the plant series; read Part 1 through this link.

L
ets continue our journey to the cen- 
ter of the plant, looking at the network
communication between the PLC and
the SCADA computer. (Part 1 of the
series explained the supervisory con-
trol and data acquisition (SCADA) system big 
picture at a glance and then followed one ana-
log signal, the tank temperature signal, from
being a physical value up to a scaled digital 
value stored in a known memory address in
the programmable logic controller (PLC) cen-
tral processing unit (CPU).)
Common communication interfaceor a
common network, both of them have an Eth-
ernet port, and they are connected together
directly, via a switch, or a network of switches.
Common languageits called a commu-
nication protocol in automation.
Known network addressesobviously, we
cant call someone on his cell phone if we
dont have his number, and the same goes
here.

Network communication  Memory addressesaddresses for the

Network communication has always been the data to be communicated in the slave or
most confusing topic for instrumentation engi- server device memory.
neers when discussing SCADA.
MORE In this example, we have a PLC with some
ADVICE information located in its memory registers (the The discussion on the industrial network
KEY CONCEPTS
tank temperature value) and a brand new com- communications can go endlessly here, but for
Network communication has puter with the latest version of XYZ SCADA now lets go back to our example and apply the
always been the most confusing topic package installed on it. A question presents same four points:
for instrumentation engineers when itself: How would the computer talk to the PLC?
discussing SCADA. Can they actually talk?  The communication interfaceIn our
Four elements must exist for The answer is they can, but for any two example, the PLC has only an RS232 seri-
any two devices to exchange data
together: common communication
devices to exchange data together, four elements al port; we have no choice but to use it
interface, common language, known must exist: and make sure the PC we buy has a simi-
network addresses, and memory
addresses.
CONSIDER THIS
See more SCADA stories and
Part 1 of this series on
www.controleng.com
CONSIDER THIS
What are other critical elements
for PLC and SCADA network
communications? Figure 1 is an example of a PC/PLC network. All images, graphics courtesy: Shady Yehia, The Control Blog

DE5 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com

 lar port too. If not, we can always buy a
PCI serial card and plug it into the moth-
er board of the PC. We bought the seri-
al cable and made sure it has the correct
pin-assignment and plug it into the serial
ports in both sides.

 The communication protocolThis

PLC talks one of the most common com-
munication protocols in the world, the
modbus.

 Known addressesAs the modbus seri-

al protocol allows only one master on the
network, and only the master can initiate
communication requests, the master needs
no address. The PLC modbus slave address
is set to 01.

 Data addressThe temperature value is

MW100, which is explained in part 1 of
this article.
Figure 2 is an example of SCADA connectivity before OPC
Natively, computers and their operating sys- technology.
tems dont speak modbus; its the software that
runs on the computer that provides this. If the
SCADA does not speak modbus, then an OPC
server in the middle that can talk with the
SCADA and the modbus is needed.

OPC server, the middle man!

OPC is a software interface standard that
allows Windows programs to communicate with
industrial hardware devices:

 OPCOLE for process control

 OLEObject linking and embedding

The OPC server is a software program that

converts the hardware communication protocol
used by a PLC into the OPC protocol. The OPC
client software is any program that needs to con-
nect to the hardware, such as SCADA. The OPC
client uses the OPC server to get data from or
send commands to the hardware (see Figure 2).
The value of OPC is that it is an open stan-
dard. Users can choose any OPC client software Figure 3 is an example of SCADA connectivity after OPC technology.
they need (i.e. any SCADA software), and it can
communicate seamlessly with their hardware as
long as there is an OPC server that can talk to it
(see Figure 3).  ChannelThe user defines the commu-
OPC servers usually are very user friendly, for nication interface, communication pro-
a small application like the one we have, setting tocol, and the port used in the PC. In our
up the OPC server to do the needed job shall example it is a serial interface, the protocol
take no more than minutes. The user is usually is modbus serial, and we will use the serial
asked to configure four elements: port COM1.

www.controleng.com CONTROL ENGINEERING JANUARY/FEBRUARY 2016 | DE6

 DIGITAL EDITION exclusives

capability (like our tank temperature, we

certainly dont want to write anything on it,
we just want to read it). In our example we
have one OPC item and its named Tank
Temperature (see Figure 4).

These four elements actually represent the

Figure 4 shows an OPC
configuration, with channel,
device, group, and item.
DeviceThe user mainly defines the
node address of the PLC. In the example
shown below, there is one PLC and its
address is 01.
address of the OPC item; this address can be
called by OPC clients (i.e. the XYZ SCADA
Software). The next article in this series will dis-
cuss the SCADA software and how its tags are
defined, how information is visualized, stored
and reported, and the concept of client/server in
SCADA applications. ce

GroupAn optional item, just a fold-

er to segregate the OPC items if there are
too many. In our example we will create a
group and call it Tank.
ItemThis is the actual place that holds
the information in the OPC server. Each
item is corresponding to a memory address
in the PLC memory, and each item can
have a read/write capability or a read only
Shady Yehia is the founder and author of The
Control Blog. He is the Instrumentation, Control,
and Automation Proposals & Engineering man-
ager in a process technology integration com-
pany based in Qatar and operates in the EMEA
region. This article originally appeared on The
Control Blog. Edited by Chris Vavra, produc-
tion editor, CFE Media, Control Engineering,
cvavra@cfemedia.com.

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INDUSTRY NEWS and events

School celebrates 10 years

of success enrolling women
in engineering studies
Women comprise more than 30%
of incoming undergraduates in the
Lyle School of Engineering at Southern
Methodist University (SMU) in Dal-
las since 2005, exceeding the national
average of about 20% in American col-
leges and universities. For fall 2015, 100
of the 295 first-year students enrolled
as engineering pre-majors at SMU are
womenalmost 34% of the total.
Not only are we recruiting women,
we are accomplishing the more dif-
ficult challenge of retaining these
students, said Lyle dean Marc Chris-
tensen. But weve got to do more. Are
we bringing the best engineers to the
worlds problems? Not if women and
members of minority groups feel dis- Women students at SMUS Lyle School of Engineering with mentors at a
couraged for any reason about pursu- recent STEM event for Dallas-area girls. Left to right are: Rachel Sheppard, a masters stu-
ing engineering as a field of study or dent at SMU Lyle studying operations research; Amber Scheurer, DLP process engineer
as a career. at Texas Instruments; Jennifer Vilbig, design engineer at Vilbig & Associates; Sarah Green,
process development engineer at Dr. Pepper Snapple Group; Morgan Reiner, junior at
Software development SMU Lyle studying mechanical engineering. Courtesy: SMU Lyle School of Engineering

company acquired Success in attracting and keeping bracelets, computer programming, and

P
TC announced it has signed a defini-
tive agreement to acquire Kepware,
a software development company
that provides communications connectivity
to industrial automation environments, for
$100 million, with an additional $18 million
based on the achievement of certain stra-
tegic initiatives and financial results. The
acquisition is intended to enhance PTCs
portfolio of Internet of Things (IoT) technol-
ogy and accelerate the companys entry
into the factory setting and the Industrial
IoT (IIoT). Founded in 1995 and located
in Portland, Maine, Kepware serves
customers in more than 120 countries in
such industries as manufacturing, oil and
gas, building automation, and power and
utilities. PTC said it intends on maintaining
the Kepware partner ecosystem and con-
tinue developing and enhancing Kepware
technology.
Edited by Chris Vavra, production
editor, CFE Media, from PTC and Kepware
information.
women in the Lyle School is less about
percentages and more about all students
feeling that they are part of something
meaningful, Christensen said.
Message to grade-school youth
The Lyle School also has an active
student chapter of the Society of Women
Engineers (SWE), which is heavi-
ly involved in taking the message of
engineering for women to Dallas-area
schoolgirls through volunteer science
and engineering outreach activities.
By visiting elementary schools and
co-hosting with the Dallas section of
SWE programs like the Design Your
World STEM Conference for Girls, the
college women are hoping to help put the
younger girls on the same path they have
chosen.
At Design Your World, 150 girls
from around North Texas met at SMU
Nov. 14 for activities that teach by
doing the science behind making poly-
mer jewelry and twinkling, electronic
indoor rollercoaster racing to name a
few. This helps young girls connect engi-
neering to their own lives and see the
opportunities that are available.
If its a smaller group, we introduce
ourselves and explain our disciplines and
try to relate that to something they can
understand, said Lyle student Rachel
Ann Sheppard, who is president of the
Lyle Schools student section of SWE. I
say, Do you know what people in my
major do? We help your food get to the
grocery store in the most efficient way.
And they say, That sounds really cool.
The Lyle School will celebrate 10
years of substantial enrollment of women
throughout the 2015-16 academic year
through various programs and events.
Kim Cobb, director of media relations,
Southern Methodist University (SMU),
cobbk@mail.smu.edu. Edited by Chris
Vavra, production editor, CFE Media,
Control Engineering,
cvavra@cfemedia.com.

12 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com

 Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news

Groups collaborating for transparent industrial network structure

T
he CC-Link Partner Association (CLPA) helps increase productivity. The demand for networks is essential, which is the purpose
and Profibus & Profinet International intelligent communication will continue to of this collaboration.
(PI) are working on a close collabora- increase due to Industrie 4.0 and the Indus-
tion designed to enable transparent and trial Internet of Things (IIoT). As users pre- Edited from a CC-Link Partner Association
easy bi-directional communication between pare for these next-generation manufactur- (CLPA) and PI press release by Control Engi-
CC-Link IE and Profinet devices through
ing systems, the ability to integrate various neering, CFE Media.
standardized interfaces. A joint working
group is being established to develop nec-
essary technical specifications. When work
on the specifications is complete, it will be

Rugged Precision
available to members of both organizations
for implementation.
Digital communication using a fieldbus
or industrial Ethernet is already widely
used in modern production plants and
The MAQ20 Industrial
Data Acquisition & Control System

Industry forum
event to focus on
IIoT, information
technology trends
The 20th annual ARC Industry
Forum, Feb. 8-11, in Orlando, Fla., will
focus on topics such as the Industrial
Internet of Things (IIoT), smart manu-
facturing, Industrie 4.0, digitization, and
the connected enterprise and how these
ideas are moving past the conceptual
stages and producing real solutions.
ARC Industry Forum speakers will
discuss these topics and how they relate
and apply to many industries, such as oil
and gas, life sciences, processing, power Signal Integrity, Compact Design
generation, automotive, and aerospace.
The ARC Industry Forum will have 2 Software Packages for DAQ or T&M
workshops and innovation showcases
$17 per Channel Possible
to demonstrate some of the latest tech-
Lowest Cost in Industry
nological developments for emerging
applications in interoperability, virtual Up to 384 Channels in 19
manufacturing, asset management, oper- Instrumentation Rack
ations management, supply chain syn- Application Software from $250
chronization, and other areas.
0.035% Accuracy
Edited by Chris Vavra, production edi- 1500Vrms Channel-to-Bus
tor, CFE Media, from ARC Advisory Group Isolation
information.
PID Software Control
MORE - Up to 32 Loops with ReDAQ Shape
ADVICE - Unlimited Loops with IPEmotion
www.arcweb.com/events 40C to +85C Operating
Also visit Control Engineering events page, upper Temperature Instrument Class Signal Solutions
right, www.controleng.com. dataforth.com 800-444-7644

CONTROL ENGINEERING JANUARY 2016 | 13 input #8 at www.controleng.com/information

INDUSTRY NEWS and events
Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news

More headlines online

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:
 A3 Business Forum, Lake Buena Vista, Fla.,
Feb. 3-5
https://a3.a3automate.org/a3/BusinessForum
 20th Annual ARC Industry Forum, Orlando,
Feb. 8-11
www.arcweb.com/events/
arc-industry-forum-orlando
 Engineers Week, Feb. 21-27
www.discovere.org/our-programs/
engineers-week
 4th USA Science & Engineering Festival,
Washington, D.C., April 15-17
www.usasciencefestival.org
 CSIA Executive Conference, Puerto Rico,
April 19-22
www.csiaexecutiveconference.org
 Hannover Messe 2016, Hannover,
Germany, April 25-29
www.hannovermesse.de
Top 5 Control Engineering articles
Dec. 14-20: The most visited articles includ-
ed the Engineers Choice finalists; Arc flash
energy analysis, Electrical noise and EMI;
Fixing PID; and Choosing between PLCs,
PACs, or IPCs.
Internet of Things alliance group launched
Kepwares IoT Alliance program is a strategic
network of Internet of Things (IoT) solutions
providers with smart technology, thought
leadership, and marketing initiatives.
Manufacturing index contracts
The Institute for Supply Managements (ISM)
Purchasing Managers Index (PMI) dropped
to below the 50% growth point in November,
for the first time in three years.
Centrifugal pump market impact
Global market for centrifugal pumps is
expected to grow to over $40 billion in 2019;
slumping oil prices will influence the centrifu-
gal pump market, said IHS Inc.
Control system standards
Understanding a companys operational
technology (OT) security posture and the
developments from IEC 62443-2-4 have
added security program requirements and
benefits for industrial automation and control
systems (IACS) security and are key in pro-
tecting a companys infrastructure.
Specification on cyber security volume
ODVA announced the pending publication of
a new volume in its specifications titled CIP
Security and will be initially applicable to
EtherNet/IP.
Microsoft ends Windows XP Embedded
support on Jan. 12
Do a system inventory to assess where
attention is required.
CORRECTIONS
The article, Eliminate RF leakage currents from
drives, a December 2015 issue article, should have said
that C stands for capacitance.
Two companies that would have been included in
the 2015 System Integrator Giants list were not included
in the final tabulations in the Global System Integrator
Report, distributed with the Control Engineering and Plant
Engineering December 2015 issues.
Barry-Wehmiller: Total Gross Revenue: $100 million or
more. Total System Integration Revenue: $65 million.
Total Automation and Control Engineers Assigned to
SI Projects: 230.
Tesco Controls Inc.: Total Gross Revenue: $10 to $49
million. Total System Integration Revenue: $33 million.
Total Automation and Control Engineers Assigned to
SI Projects: 101.
See other SI Giants at
www.controleng.com/Giants

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according to IEC 61508, ISO 13849 and IEC 62061
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the integration of advanced
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However, standardization pro-
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2015 CYBER SECURITY STUDY:
Cyber security at
small-sized facilities
F
Forty-three percent of respondents
to the Control Engineering 2015 Cyber
Security Study work at a company with
fewer than 100 employees. Of these
respondents, 5% perceive a severe threat
level to their control cyber security sys-
tem, compared to 21% high, 42% mod-
erate, and 28% low. Below are five more
findings from this study as they relate to
small-sized facilities:
1. Threats: The most concern-
ing threats to cyber security systems of
small-sized facilities are malware from a
random source with no specific connec-
tion to their company or industry (41%),
theft of intellectual property (19%), and
attacks through an undetected vulnera-
bility in a network device (16%).
2. Vulnerable system components:
The most vulnerable system compo-
nents within small-sized facilities are
computer assets (65%), network devices
(65%), connections to other internal sys-
tems (60%), and wireless communication
devices and protocols used in the auto-
mation system (55%).
Computer emergency response teams at small-sized facilities
Well-trained, capable of detecting
incidents
15%
31%
18%
Does not exist
Exists but not currently well-trained
Half of computer emergency response teams at small-sized facilities appear well-
trained and capable of detecting and/or responding to cyber-related incidents.
Courtesy: Control Engineering
www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION
16 | JANUARY 2016 CONTROL ENGINEERING
research
3. Vulnerability assessments: Fifty-
three percent of small-sized facilities have
performed some type of vulnerability
assessment within the past 12 months.
The average small-sized facility has
checked its vulnerabilities within the past
6 months.
4. Cyber-related incidents: Forty-
two percent of small-sized facilities have
experienced at least one malicious cyber
attack on its control system networks and/
or cyber assetsthat they were aware
ofwithin the past 24 months, with 33%
being aware of 2 or more attacks.
5. Identifying incidents: Two-thirds
of small-sized facilities were alerted about
recent cyber incidents by members of
their internal teams, while 15% were dis-
closed by a third-party assessment, and
12% were notified by the government or
other outside party.
Amanda Pelliccione is research director at
CFE Media, apelliccione@cfemedia.com.
View more information at
www.controleng.com/2015CyberSecurity.
Well-trained, capable of responding
to incidents
15%
21%
Well-trained, capable of
detecting and responding to incidents
Top 3 job satisfaction
factors
44%
39%
28%
Technical
T h i l F
Feeling
li off Financial
Fi i l
challenge accomplishment compensation
Out of 18 possible factors, this
chart displays the top three with
the greatest impact on job satis-
faction among end users. Source:
Control Engineering 2015 Career
Study
>50%
of system inte-
grators agree that engineering
and project management skills
and knowledge of current indus-
try standards are very helpful for
quality work. Source: Control Engi-
neering 2015 System Integration
Study
4 in 10 end users
believe the Industrial Internet of
Things (IIoT) and Industrie 4.0 to
be two sides of the same coin.
Source: Control Engineering
2015 IIoT, Industrie 4.0, Informa-
tion Integration Study
52%
of end users are
concerned about the vulnerability
of their companys project files
and control system operational
procedures. Source: Control Engi-
neering 2015 Cyber Security Study
More research
Control Engineering surveys its
audience on several topics each
year: cyber security; career survey;
system integration; IIoT, Industrie
4.0, information integration; and
mobility, Ethernet, and wireless.
All reports are available at
www.controleng.com/ce-research.
www.controleng.com
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Control Engineering International
Changing from made
to created in China
Control Engineering China conducted an in-depth interview with Wang Chunwen, global vice
president and general manager for China Honeywell Process Solutions, on how to help Chinese
process industry achieve a successful transformation from Made in China to Created in China.
W
With the slowdown in econom-
ic growth and the increasing global competi-
tion, Chinas process industry has encountered a
number of challenges in performance improve-
ment, cost reduction, and industrial upgrade.
How can the Chinese process industry success-
fully transform from Made in China to Cre-
ated in China? To answer the question, Control
Engineering China interviewed Aldous Wong,
vice president and general manager, China Hon-
eywell Process Solutions (HPS).
Big data technology
Regarding efficient collaboration, Wang said,
one of the core characteristics of Intelligent Plant
is to use big data. Through acquisition, processing,
and analysis of big data, not only can the future
operation be optimized, but also underlying risks
can be reduced and nipped in the bud. Therefore,
in some way, the Intelligent Plant may be consid-
ered as a concept built on big data.
Big Data technology is widely used among
developed countries by process industrial enter-
prises to deeply explore the market potential,
which, to some extent, raises their profitability in
return. And in the future market competition, big
data occupation and utilization capability will be
critical to the competitiveness edges. Wong added,
big data analysis can directly reflect basic oper-
ation condition of [a] plant. Intelligent Plant
solutions provided by us can help plant man-
agers and onsite operators establish emergency
mechanism[s] to make the smartest and promptest
decisions in case of emergencies, to reduce fore-
seeable risks, and to raise operation performance.
Application of automation is more mature in
Chinas process industry, especially in the petro-
chemical industry, compared to those in discrete
industries. Many companies face difficulties, such
as how to achieve information integration through
the industrial chain and how to conduct specific
analysis and optimization with scattered big data. A
global supplier of process automation can provide
intelligent process automation solutions for plants
intelligent instruments, control systems, databas-
es, software, and other solutions. Implementations
can benefit China National Petroleum Cooperation
(CNPC), Sinopec, and China National Offshore Oil
Cooperation (CNOOC), he said.
Customized solutions
The challenge is to bring custom-made solu-
tions up to speed with global technological
advances in process industry development. Cus-
tomer feedback improves process control industry
products, Wong said, especially in vertical indus- Aldous Wong, vice
tries like [the] mineral industry, pharmaceutical president and general
industry, and power industry. manager, China Honey-
Traditional automation for mining and bene- well Process Solutions
ficiation of large molybdenum and copper ores is (HPS). Courtesy: HPS,
completed with programmable logic controllers Control Engineering
(PLCs) and supervisory control and data acquisi- China
tion (SCADA) software, but programming, opera-
tion, and maintenance have challenged customers.
Modern products provide easy availability, con-
figuration, and adjustment, which significant-
ly shortens time for configuration programming,
screen design, report configuration, and commu-
nication configuration. Products also can provide
real-time, decision-making information for cus-
tomers without disturbing the operators moni-
toring to process, which simplifies the equipment
operation. Modern systems with flexibility and
extendibility are essential for improving plant per-
formance and operation achievement.
Energy emphasis
Expected growth rate of energy consumption in
the 13th Five-Year Plan will be approximately 3%.
In the face of energy structural changes and
market transformation, we also perceive the
demand of customers in energy efficiency manage-
ment, environmental protection, energy conserva-
tion, cost-benefit control, etc. Wong added, We
have always valued the future development of ener- MORE
gy market. Companies need to forge a green envi- ADVICE
ronment and satisfy energy demand since this has
This was translated and edited for
become our development objective. ce
Control Engineering from Control
Engineering China.
Aileen Jin, editor-in-chief, Control Engineering www.cechina.cn
China. Edited by Joy Chang, digital project manag- See other international coverage.
er, Control Engineering, jchang@cfemedia.com. www.controleng.com/international
CONTROL ENGINEERING JANUARY 2016 | 17
 COVER STORY automation upgrades

More intelligent and efficient

PLC programming
IEC 61131-3: Whats the acceptance rate of this control programming standard? Ladder
diagram remains the simplest and most popular approach for PLC programming, but may not be the
most efficient way, according to Control Engineering research, in cooperation with AutomationDirect.

A
lthough the IEC 61131-3 Program- specifying or PLC programming. The results of the
ming Languages standard has been survey show low awareness and limited adoption
around for nearly 25 years, limited of this standard in North America, indicating that
awareness of its scope and features situations where its application is required are rare.
has kept it from becoming a require- The most common job functions of the respon-
ment in North America. A recent survey of Con- dents were system or product design; control or
trol Engineering readers showed that ladder logic instrument engineering; or system integration or
remains the most popular programming method consulting. These accounted for more than 60%
for programmable logic controllers (PLCs). Find- of respondents. About one-third of functions
ings of the custom research project, on behalf of included process, production, or manufacturing
AutomationDirect, suggest that programmers engineering; operation or maintenance; or other
could save time and money by using other stan- engineering. Almost 10% of participants were in
dard programming languages more often. Diffi- general or corporate management, and this group
culty in code transportability among PLC brands was more likely to specify but not program PLCs.
may be an issue. More than 60% of respondents were employed
at companies with more than 100 employees, some
Overview: limited adoption with 1,000 or more. Almost 40% worked at compa-
More than 585 responses were received from nies with fewer than 100 employees.
participants who met eligibility requirements, By company type, PLC end users were the larg-
including relevant purchasing influence and est group of respondents at almost 40%, and almost
authority, and also responsibility for hardware half of the respondents were system integrators,
MORE
ADVICE
KEY CONCEPTS
Survey results: 85% of Control
Engineering readers were unfamiliar
with or somewhat familiar with IEC
61131-3.
Programmers working in North
America dont seem to need this
functionality since ladder diagram and
function blocks often can be solve
requirements.
Perhaps the standard will become
more widely deployed in North
America.
ONLINE EXTRA
Another table shows more details
on the use of IEC 61131-3.
CONSIDER THIS
What efficiencies are missed Figure 1: How familiar are you with the IEC 61131-3 programming standard? About 85% of the respon-
without wider IEC 61131-3 use? dents dont know much about it. Figures, images, and table courtesy: AutomationDirect

18 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com


original equipment manufacturers (OEMs), or
machine builders. The respondents were widely
spread throughout the United States.
What the experts say
The IEC 61131-3 standard has been around for
nearly 25 years and includes a family of program-
ming languages. IEC characterizes it as an interna-
tional standard for programming PLCs. PLCopen,
a nonprofit industrial trade organization, is mostly
dedicated to IEC 61131-3 and contains significant
information about the standard.
PLCopen says IEC 61131-3 is the only glob-
al standard for industrial control programming.
It harmonizes the way people design and operate
industrial controls by standardizing the program-
ming interface. The group says it is a standard pro-
gramming interface with a common structure.
The standard includes a definition of the
sequential function chart (SFC) language, used to
structure the internal organization of a program.
It adds four inter-related programming languages
including two graphical ones, ladder diagram (LD)
and function block diagram (FBD); and two text-
based languages, instruction list (IL) and struc-
tured text (ST). Using logical elements, defined
data types, task structure and scheduling, and exe-
cution control, each program can theoretically be
structured to increase re-usability, reduce errors,
and increase programming and user efficiency.
PLCopen has been working with technical com-
mittees to add extensions to the standard. There
have been a number of functions added as a result
of these activities including motion control, safety,
OPC Unified Architecture communication (OPC
UA from OPC Foundation), XML schema, reus-
ability level definitions, and conformity level.
www.controleng.com
Figure 2, COVER
IMAGE: Second most
popular programming
language is function
blocks. Once ladder
diagram programming is
So how familiar are PLC purchasers and pro-
removed, there are four
grammers with IEC 61131-3?
options in the second
When Control Engineering polled its readers,
tier of programming
85% of respondents said they are either not familiar
methods, with func-
with or only somewhat familiar with it (see Figure
tion block diagram as a
1). While this standard may have great acceptance
strong choice for a sec-
and use in Europe or other parts of the world, it
ond programming lan-
has not had as much impact in North America.
guage. Facts Engineer-
Implementing it does not appear to be a priority
ing PLC image courtesy:
or a requirement for many U.S. respondents since,
AutomationDirect
after more than 20 years, an overwhelming major-
ity of programmers working in North America are, Engineering
at best, only somewhat familiar with the standard. interaction: The site
More than 40% of respondents reported no poll in January at
familiarity with the standard, and the highest con- www.controleng.com
centration of these respondents was among those asks what you think the
who say they are PLC programmers. Among those most useful PLC pro-
who say they actually write programs, only 15% gramming language is
claim a high level of familiarity. after ladder logic.
Users suggest code interoperability sounds
good but is hard to implement.
Why use PLCs supporting a standard?
Among the respondents who use or speci-
fy PLCs, and who say they are familiar with IEC
61131-3, the next question asked in the survey was
why they use it. The answers suggest its use does
not appear to be a requirement for most in North
American industrial automation markets. The rea-
son cited most often (39%) is simply because the
PLC product came with the language. A quarter of
the end users specified IEC 61131-3 programming
language, and some of this can be attributed to U.S.
companies shipping machines into Europe or Asia.
CONTROL ENGINEERING JANUARY 2016 | 19
COVER STORY automation upgrades
Fewer than 10% of the applications demand
the features of IEC 61131-3, and a larger percent-
age of respondents who dont program PLCs say its
because its specified, hinting that some of the totals
are driven by hardware choice and selection.
User programming preferences
When 545 respondents were asked which lan-
guages and features were very important, ladder
diagram was the predominant programming lan-
guage (see Table), with function blocks as the run-
ner-up. In a second function block question, most
say they use function blocks within a ladder dia-
gram. The ability to create custom function blocks
and embed them in ladder logic is viewed as an
important feature of PLC programming.
Its not surprising to see structured text lan-
guage surpass other text-based programming
methods. However, it is interesting to note both
instruction list and statement list exceed the use
of C or Basic languages. Clearly, respondents were
Dave Regester, a tech- using PCs to create C or Basic code and down-
nical support specialist at load to their PLCs, although this is a feature often
AutomationDirect, works supported by the hardware and software. Pro-
through a customer ques- grammers working with Microsoft .Net and other
tion, online and on the PC-centric programming technologies would likely
phone while testing the have a different list of very important items.
actual controller hardware
in the tech support area. Transportability is not a reality
One of the goals of the IEC-61131-3 standard
is to provide customers the ability to develop algo-
rithms and software code in one vendors program-
ming environment using an IEC-61131-3 language
and then transport it to another vendors environ-
ment with few or no changes. In discussions and
internal research, users suggest code interoperabil-
ity sounds good but is hard to implement.
Software export and import functionality is
not easily achieved, and in many cases, the true
extent of the interoperability is questionable.
Users find themselves having to rewrite pro-
Respondents: grams when moving between dif-
ferent vendor controller platforms.
Most important In some cases these transportabil-
languages, features ity functions mitigate the amount
Program Importance of rewriting but do not eliminate it
Ladder diagram 85% entirely. The vendors are to blame
Function block diagram 49%
for this to some extent since not
all vendors follow the standard as
Ability to create custom
function blocks
48% needed for portability.
Perhaps the transportability level
Structured text 29%
that end users require is beyond
Sequential function
charts
27% what vendors are willing to provide,
as it would necessitate cooperation
Instruction list or
statement list
23% among vendors that would reveal
extensive PLC hardware and pro-
C 10%
gramming software design details,
Basic 10%
probably an unrealistic goal.
20 | JANUARY 2016 CONTROL ENGINEERING
Although respondents cited ladder diagram
as the most important language 85% of the time,
respondents also strongly recommended function
block programming (see Figure 2), at 51% as a
second language choice for a PLC.
Of the other three programming method-
ologies specified by IEC 61131-3sequential
function charts, instruction list, and structured
textnone were listed by more than 13%. IEC
61131-3 has not had great effect on the U.S. PLC
market. Programmers working in North Ameri-
ca dont seem to need this functionality since, in
many cases, ladder diagram and function blocks
can meet requirements. When one of these three
methodologies would be a better technical choice,
use may be limited due to a lack of familiarity
among respondents.
A collaborating survey
In a similar survey, AutomationDirect polled
existing PLC customers and found results to be
very similar to Control Engineerings survey in
regard to knowledge, use, and acceptance of IEC
61131-3. More than 75% of AutomationDirects
customers were unfamiliar with the standard.
Most users surveyed had not used a PLC designed
or programmed in compliance with IEC 61131-3.
Ladder diagram programming was the most com-
mon; function blocks was a strong second place.
PLC applications often dictate the use of
advanced programming languages and techniques.
While ladder diagram remains the simplest and
most popular approach, it may not be the most
efficient way to program, nor does it offer some of
functions available with more sophisticated lan-
guages. Function blocks are the next language of
choice of U.S. programmers and specifiers of PLCs,
and as an added bonus, they come in different
forms such as embedded within ladder diagram,
standalone function block diagram programming,
and custom, user-defined function blocks.
The IEC 61131-3 standard has been around for
more than 20 years, and functionality continues to
be added. It has become a standard in Europe and
other areas of the world, and interest in its adop-
tion in North America is likely to grow.
Some U.S. OEMs, machine builders, and system
integrators that ship products or systems to other
areas of the world use it routinely. Most U.S. users
have yet to fully accept its value proposition. Until
it is more widely deployed, ladder diagram and
function block programming will continue to bring
automation to life for most PLC programmers. ce
Jeff Payne, product manager at Automation Con-
trols Group, AutomationDirect. Edited by Eric R.
Eissler, editor-in-chief, Oil & Gas Engineering,
eeissler@cfemedia.com.
www.controleng.com
 Learn about
our no
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 COVER STORY OT gets help from IT

IT helps in the
evolution of controls
Over the past decade there has been a paradigm shift in the structure of how companies
organize information technology (IT) and controls sectors, with the former having increasing
influence in some areas traditionally run by the latter. As IT and operations technology
(OT) data converge, so do the physical departments, and this has some major implications
for the controls department.

MORE
ADVICE
KEY CONCEPTS
Get IT involved in projects early to
ensure smooth transitions.
Get the controls department on the
cloud for data sharing.
With IT helping the controls indus-
try, controls vendors and integrators
have to shift their approach.
GO ONLINE
Learn more on this IT/OT conver-
gence and related topics with this
article online at
www.controleng.com, including:
Considerations when IT is involved
and info on software maturity levels.
CONSIDER THIS
As IT and OT data converge,
so do the physical departments,
with implications for controls.
T
oday, more companies than ever are
relying on information technology
(IT) personnel to perform the most
vital part of their controls projects:
procurement. This customer shift is
reshaping the controls industry. Controls ven-
dors and integrators must respond by approach-
ing their market in different ways.
A changing market brings challenges and
opportunities, and some suppliers will fail to
adapt to new customer needs. Others will take
advantage of the shift in buying power to better
compete in their fields.
To understand the way IT is changing the
controls market, it is helpful to know what has
driven this shift over time.
Ethernet as a bus
Ethernet has long been the standard IT com-
munication medium. It has served as the dividing
line between the controls and IT groups. Any-
thing Ethernet-related was IT, and anything bus-
oriented was part of the controls realm. However,
this barrier has dissolved over the past decade.
Currently, most customers prefer Ethernet as
their controls bus. It is easy to deploy with avail-
able staff or contractors. It fits into existing infra-
structures, and IT groups manage it using proven
tools and practices.
As a result, dedicated controls staff are no lon-
ger needed to maintain controls networks. In
many cases, IT has assumed this role. They usu-
ally work directly with integrators to design net-
works for controls projects.
Security is an IT thing
Recent cybersecurity attacks on controls tech-
nologies have made companies rethink secu-
rity approaches used. Few organizations have a
dedicated staff to manage security in this realm.
Companies rely on the only cyber-security team
they have: the IT group.
Unfortunately, there are few outside organiza-
tions that can help IT in this area. Cyber security
for controls is a new field with little standardiza-
tion. The current approach to this problem is to
adapt procedures from the only place they can
IT standards.
IT now bears the responsibility of solution
architecture for controls projects. Besides secu-
rity, this obligation brings with it the full lifecy-
cle requirements of a solution. IT groups must
involve themselves throughout a controls project
to meet these needs.
Staff reductions
All organizations seek to improve the bottom
line. Many companies have reduced staff in mul-
tiple areas to increase profits, and controls staff
has been particularly affected because some of
their responsibilities have shifted to IT.
This has caused a snowball effect in some
organizations where companies assign fewer
responsibilities to their reduced controls staff,
give the tasks to the IT group, then reduce the
number of controls staff.
As technology blurs the lines between the
two groups, controls staffs are being forced to
work under IT constraints. Many IT groups have
moved to a remote operations model, where
onsite staff is no longer needed. Controls groups
face similar challenges.
How money influences decisions
These changes to the controls and IT environ-
ments have culminated into a driving factor: IT
controls the money for some higher level proj-
ects. When IT is a primary stakeholder in com-

22 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com

puter and networking projects for controls, IT
departments may receive some budget allocations
that previously went to controls engineers. In
some organizations, for networking and comput-
er-based hardware, IT has become the primary
buyer for operations technology (OT) personnel.
IT as the primary customer
IT-centric customers shift purchasing trends,
changing the way vendors design and market
products. These customers change how inte-
grators sell their capabilities. And the shift
changes what customers view as success. The fol-
lowing are some successful examples from an IT
perspective.
 Support
Support is the primary role for IT groups.
They have invested in tools and processes to
manage support activities. Innovations and stan-
dards, such as remote access, have reduced the
burden on IT operations.
IT groups expect controls products to fit into
these existing support approaches. IT needs to be
able to solve problems quickly using their sup-
port hierarchy. Common problems should have
simple solutions that first-level support person-
nel can perform. Products need to provide useful
diagnostics in standard ways.
For example, products should support simple
network management protocol (SNMP).
Products also should incorporate routine
maintenance as a primary activity. IT should be
able to track and update firmware with existing
tools. Products should be easy to replace if a fail-
ure occurs.
And support documentation should be avail-
able on the device itself (using Web-based stan-
dards, for example). Controls products should
not place an extra burden on the staff that sup-
ports them.
 Security
The adoption of IT security standards with-
in controls products has been a slow process.
The most important IT security need is for
devices to integrate with common authentica-
tion schemes. Products should support Light-
weight Directory Access Protocol (LDAP) for
user access.
Managing credentials for a large amount
of devices is the second biggest IT need. This
applies to devices that do not provide LDAP
integration and have their own security mea-
sures. Vendors should offer a simple way to
update device security information en masse.
www.controleng.com
With recent shifts
 Procurement for some companies,
Controls products are notorious for long purchasing dollars are
part numbers and many options. This makes rolling away from the
the procurement process difficult for IT person- controls team toward
nel. IT expects standard ordering schemes and the responsibility area
reduced options to simplify the buying process. of the IT department
Computer and networking products for OT for networking and
can be difficult to purchase because some do not computing hardware.
include everything in the box. Instead, cus- Courtesy: Leidos
tomers buy each component as a separate item.
IT often thinks of their products as appliances
rather than bundled sets of items.
For example, IT-related products, or those
expected to integrate with IT communications,
should have integrated 120 V ac power and Eth-
ernet connectivity.
 Deployment Controls
IT staff often expect that devices are easy to
install and configure. Products should assist the products should
user during the installation process by using
standard techniques. Networked products not place an
should incorporate auto-discovery. IT prefers
convention over configuration to accommodate extra burden
the most common deployment scenarios.
IT views external configuration and deploy- on the staff
ment tools as a liability to their technology debt.
They expect devices to have integrated Web that supports
servers and hosted Web applications for ease of
management. them.
This allows IT to reduce their application
maintenance footprint and manage devices in a
standard way.
Whats next?
Agile product vendors and advanced integra-
tors can prosper using well known information
technology examples, standards, and expecta-
tions. ce
Corey Stefanczak is senior system architect at
Leidos, #4 System Integrator Giant for 2015 and
a prior System Integrator of the Year winner.
Edited by Eric R. Eissler, editor-in-chief,
Oil & Gas Engineering, eeissler@cfemedia.com.
CONTROL ENGINEERING JANUARY 2016 | 23
CLOUD historian value

Data historians:
value from big data in the cloud
Data historians help collect, store, and retrieve process data in cloud-based applications,
comparative analysis, and quality improvement in the Industrial Internet of Things (IIoT).

D
ata historians help manufacturers to
collect, store, and retrieve the mas-
sive amount of process-related data
needed for comparative analysis and
quality improvement in the Industri-
al Internet of Things (IIoT). At the very least, a
premium data historian should have the capabil-
ity to log data from IIoT devices at speeds greater
MORE than 100,000 tags per second and work with mul-
ADVICE tiple data sources across an enter-
KEY CONCEPTS prise, such as OPC UA servers, OPC
Historians help manufacturers collect, store, DA servers, OPC XML DA serv-
and retrieve data. ers, BACnet devices, SNMP devices,
Seamless historian integration with cloud- and many others. A data historian
based storage and applications helps with that integrates with the cloud stands
secure information sharing, where needed.
out by providing fast storage and
Scalability, security, and mobility are important
attributes for a cloud-based data historian.
retrieval of an organizations big data
resources.
GO ONLINE
See links with this article online at
www.controleng.com. Data storage, access, analysis
CONSIDER THIS A cloud-based data historian
Can you connect securely from anywhere? should store vast amounts of data
and easily integrate with tools to analyze that data
and turn it into actionable information. It should
enable access to big data from any desktop, Web
browser or mobile device, tying into a trusted
cloud infrastructure.
The cloud-based data historian should use
connection technology that leverages a public,
private, or hybrid cloud infrastructure to increase
collaboration and efficiency without comprising
security. That same cloud connector technolo-
gy can act as the on-premises appliance to store
and forward data from the plant floor to a pub-
lic or private cloud. It should provide real-time
and historical data from IIoT devices, such as
meters, sensors, and processors, to and from the
cloud with security and remain IT-friendly with-
out mandatory changes to firewalls or corporate
infrastructure.
Selecting a premium cloud-based data his-
torian should be based on scalability, security,
and mobility. Users should be able to view and
perform advanced analysis on historical data at
any time, from anywhere, and on any device. A
scalable system should allow for simple merg-
ing between historian nodes, allowing on-prem-
ises and on cloud-based servers to provide data
for historical aggregation. It should be easy to
add new sites or more data, to scale for expan-
sion. A secure system combines private and
hybrid cloud solutions with on-site storage to
ensure data security and integrity with visibility.
It should safely store data in the cloud without
creating an opening for attack.
A mobile system provides the means to con-
nect to data where users are, using favorite
devices. It should aggregate metrics through the
data historians performance calculations to an
organizations decision makers wherever and
whenever needed. ce

Iconics Hyper Historian is a cloud-based data historian that uses connec- Melissa Topp is director of global marketing at
tion technology that leverages Microsoft Azure, a public, private, or hybrid cloud Iconics Inc. Edited by Mark T. Hoske, content
infrastructure to increase collaboration and efficiency without comprising security. manager, CFE Media, Control Engineering,
Courtesy: Iconics mhoske@cfemedia.com.

24 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com

CLOUD big data applications
Big data
and cloud for manufacturing
Industrial Internet of Things (IIoT), Industrie 4.0 applications, and basic electronic services are
moving from local servers into the cloud, using Internet-based software as a service (SaaS).
ONLINE: See four ways to launch IoT project.
I
ndustrie 4.0 and Industrial Internet of Things
(IIoT) discussions often focus on advanced
connectivity. Connectivity is important for
implementation and the entire enterprise
infrastructure and system architecture should
be considered. For years, businesses have main-
tained on-site server hardware that hosts e-mail,
databases, and other applications, such as enter-
prise resource planning (ERP) systems. In todays
hyper-connected world, even some of these basic
electronic services are moving to the cloud, using
Internet-based services rather than local servers.
Software as a service (SaaS) applications also are
in use for IIoT and Industrie 4.0 implementations.
Machine builders
Why use the cloud, and how is it being used?
One prevalent application is when machine build-
er original equipment manufacturers (OEMs) and
the equipment end users leverage cloud-based ser-
vices to monitor machines remotely. Implementa-
tions can span several enterprise networks to log
information to cloud databases, and collect and
analyze energy consumption data, production
data, or sensor values, providing significant value
for manufacturers. Data analysis can yield action-
able information that populates the dashboards
of decision makers to intelligently improve facili-
ties and manage predictive maintenance. Notifica-
tions and alerts, when a production line is down
or when machines will need attention, can be sent
from cloud-based messaging services via e-mails
and push notifications to mobile devices.
Cloud-based services for industrial applications
are growing rapidly, and the associated technolo-
gy is evolving at a parallel velocity as these innova-
tions find wider applications beyond the IT space.
Services can be useful for industrial data collection
and analysis. One cloud-based hub for IoT creates a
simple, fully scalable method to connect industrial
equipment and devices to that hubs cloud services.
Modern controls vendors are implementing leading
www.controleng.com
IoT protocols, including MQTT [a messaging
transport protocol] and advanced message
queuing protocol (AMQP), to further
streamline cloud-services integration. The
barriers to entry when initiating smart fac-
tory development are far lower when these
next generation cloud concepts are applied
in industrial applications.
Data, where and when needed
With more connected devices and more data
being collected, manufacturers need advanced ana-
lytics to help convert raw figures into actionable
information and an operations plan. Basic machine
analysis includes threshold monitoring of digital
and analog values and operational timing analysis
such as total, minimum, maximum, and average,
program state analysis, and energy usage calcula-
tions. Data can be stored in standard formats and
compressed, locally in the controller, in a cloud-
based solution, or on a server in the enterprise net-
work or in a public cloud as needed.
Another data analysis benefit is insights into
predictive maintenance. Logging data from oper-
MORE
ating hour counters, frequency analysis, or root-
mean-square (RMS) calculations can enable
ADVICE
high-performance condition monitoring. The sys- KEY CONCEPTS
tem facilitates limit value monitoring for differ- Cloud-based software as a service
ent process data. Pattern recognition for detecting can host applications to optimize
industrial machines.
irregularities and repetitions in the recorded data
Industrial Internet of Things
further improves process-sequence reliability. integration tools make easier.
In a real-world case, a machine OEM config-
Optimization and continuous
ured all machine controllers with the ability to improvement advance with analytic
send operational data from the machine to the tools.
cloud, over one Internet connection. Data included GO ONLINE
alarms, runtime and downtime, average cycle time, See four ways to launch an IoT
controller CPU temperature, and product size. ce project, analytics and OEE, and better
asset utilization with this article
online at www.controleng.com.
Daymon Thompson is automation product special-
CONSIDER THIS
ist, Beckhoff Automation. Edited by Mark T. Hoske, IIoT and Industrie 4.0 initiatives aim
content manager, Control Engineering, to improve manufacturing productiv-
mhoske@cfemedia.com. ity; are you implementing them?
CONTROL ENGINEERING JANUARY 2016 | 25
 CLOUD machine health matrix
Baselining, trending
machine data
Using applications of the Industrial Internet of Things (IIoT), plant managers can collect
and analyze equipment life-cycle data to weed out flaws and failures.
MORE
ADVICE
KEY CONCEPTS
Create a matrix of time-stamped
data for troubleshooting failures.
Data volume pose a challenge, and
on-premise storage risk loss.
CONSIDER THIS
How do you collect data on machin-
ery? Is it effective?
GO ONLINE
www.controleng.com has a related
links with this online article.
This screen shows the data
points painted on a piece of
equipment and the data the
points have been collecting
over time. Courtesy: Fluke
26 | JANUARY 2016
O
ut of necessity, many plants run a
patchwork of strategies to main-
tain systems, relying on run-to-fail
strategies or scheduled preven-
tive calibration along with period-
ic troubleshooting of glitch-prone components.
Short of refitting a whole plant with new
devices, there is an Industrial Internet of Things
(IIoT) strategy suitable for nearly any plant:
bootstrapping a condition-based program to
identify anomalies.
This kind of strategy employs wirelessly con-
nected hand-held test instruments connected to
smartphones and to the cloud. Managers, engi-
neers, and technicians can then employ soft-
ware to organize the data into a machine health
matrix that, along with associated analytical
tools, aids in preventive and predictive main-
tenance. This kind of condition-based program
can also aid troubleshooting and root cause
determination.
CONTROL ENGINEERING
Control applications can benefit from base-
line and trending analyses, including variable
frequency drives (VFDs) and associated rotating
equipment (motors, pumps, etc.); control loops;
programmable automated controllers (PACs)
and programmable logic controllers (PLCs); and
pneumatic components.
The sheer volume of data produced in plants
can pose a challenge, and on-premise storage can
risk data loss from corrupted hard drives, fire, or
other disasters. What company hasnt struggled
with how to organize all the data and securely
provide access to the people who need it? As time
marches on, software and data storage evolve.
Even with a computerized maintenance man-
agement system in place, its difficult to analyze
data collected by the typical range of technolo-
giesvoltage, temperature, current, and vibration.
Its a time-consuming task to assemble a holistic
view of failure patterns for all plant assets.
Failing to isolate the source of an intermittent
voltage spike on a PLC input at a critical line may
cause troubleshooting teams to overcompensate
by recommending the replacement of the whole
device, while only one element was at fault. Yet
that will still not solve the underlying problem.
Consider how technologically advanced and
wirelessly connected tools, such as thermal imag-
ers, power quality analyzers, digital multimeters,
handheld oscilloscopes, resistance testers, and
more would enable systematic data collection
along the line. The goals are to:
1. Create baselines of critical equipment
during normal operation
2. Continue to capture the same measure-
ments over time so when failure occurs,
the data can be used to determine failure
mode patterns.
Connect instruments, create a baseline
A team is assigned to create and catalog test
points of each individual piece of equipment in
www.controleng.com
 Technical
Learning
Visit omega.com for Flow Visit omega.com/
technical-learning

Measurement and Control

web-based software: painted targets on motors and near belts
for Industrial Applications
where infrared images are taken, voltage inputs and outputs OMEGA Introduces
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multiple test points and multiple pieces of equipment.
When the line is running at normal operating conditions;
technicians take baseline measurements at each test point
with the connected test instruments and move on down the
line. The initial test samples could be averaged across several
identical pieces of equipment operated in the same applica-
tion to create a standard deviation (one sigma).
The technician saves data to the specific test point and
machine and automatically uploads data from the test instru-
ments to the cloud, with a smartphone. (In some cases, engi-
neers may choose to log measurements, with a voltage module
or power quality analyzer, for example, over longer periods LCD Display
of time.) Those measurements are also immediately sharable 4 to 20 mA Output
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ments not only from the device under test, but also Visit
other machinery that might be impacting that device. omega.com/fmg80a
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and Controller

Comparison and analysis

When performing the analysis: CDTX-111/
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n Check status changes and thresholds set that were Starts at
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n Use the softwares ability to compare data from the vari-
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COPYRIGHT
COPYRIGHT 2016
2011 OMEGA
OMEGA ENGINEERING,
ENGINEERING, INC.
INCALL
ALLRIGHTS
RIGHTSRESERVED
RESERVED
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.

CONTROL ENGINEERING JANUARY 2016 | 27

CLOUD machine health matrix
events occurring with the PLC and
associated devices.
Answer questions such as:
 Were the voltage waveforms on the
PLC outputs malformed?
 Did infrared inspection test points
show temperature spikes?
Think Inside the Box.
Complex logic, multi-axis motion, visualization & IT connectivity
all in one multi-core enabled controller.
input #13 at www.controleng.com/information
 Did the level of vibration increase on
the motor powering the conveyor?
The creation of a matrix of time-
stamped data from multiple test instru-
ments over time, facilitates finding the
root cause of failures in a system. Rath-
er than viewing one measurement on
one machine, data can be correlated and
analyzed with multiple types of measure-
ments from individual machines, as well
as compared with other critical equip-
ment in the same system.
Wireless test tools,
cloud-based software
Cloud-based software and connected
wireless test tools can allow users to:
 Aggregate all data without the errors
prone with manual data collection
or the cost of labor associated with
collecting and organizing the data.
 Gather historic performance data
and establish valuable performance
baselines.
 View all the data on one screen,
trying to avoid managing multiple
pieces of software.
 Correlate multiple data points,
such as voltage, current, and ther-
mal images, to allow the spotting of
irregularities quickly.
 Get multiple data points and trend
graphs to compare each piece of
equipment, which helps preventive
maintenance planning and meets
uptime goals.
 Access immediate updates on asset
status from the field because techs
can use their mobile phones to
change the status of suspect equip-
ment from normal to at risk.
 Collect system characteristics and
supporting information, consis-
tently, no matter what shift works
on a problem.
Over the long-term, having access to
this kind of smart data on file in an easily
accessible place will help everyone on the
team. Questions such as the following
will become answerable: Has this hap-
pened before? Has anyone looked into
this previously? ce
Glenn Gardner is business development
manager for Fluke Corp., and Jeff Black is
managing editor, global content, for Fluke
Corp. Edited by Eric R. Eissler, editor-in-
chief, Oil & Gas Engineering,
eeissler@cfemedia.com.
28 | JANUARY 2016 CONTROL ENGINEERING
PROCESS flow measurement
Overcoming
flow measurement
challenges
Matching the flowmeter to the application can help engineers overcome
flow measurement issues. Magnetic, vortex, and differential pressure
(dP) flowmeters are the leading technologies used to measure
volumetric flow or flow velocity. Know when to use each.
V
olumetric liquid flow is one of the
most important parameters for
process monitoring and control in
many industries including chemical,
refining, oil and gas, water/waste-
water, power, pharmaceutical, food and bever-
age, and others.
Flows must be kept within safe limits; moni-
toring flow rates indicates when low or high flow
conditions have been breached. These excur-
sions often are provided as alarms to operators.
For real-time control, flow rate can be used as an
interlock within the control systemfor exam-
ple, to turn on a centrifugal pump before a tank
or vessel runs dry.
Perhaps the leading use of flow measurement
information is to optimize continuous processes
as the process variable in a proportional-integral-
derivative (PID) control loop. For example, a flow
measurement can be used as the process variable
feedback in a control-valve positioning loop to
keep the setpoint at or near its desired value.
The three leading technologies used to mea-
sure liquid volumetric flow are differential
pressure (dP), vortex, and magnetic flowme-
ters. Selecting among these three measurement
methods for a particular application is often
based on which technologies have been suc-
cessfully used before under similar circum-
stances. Consulting with a flow measurement
specialist at an engineering or system integra-
tion firm or a trusted supplier can provide addi-
tional insight, including the identification of
alternatives, or information regarding recent
innovations that may further improve flow mea-
surement and plant performance.
www.controleng.com
Measurement chal-
lenges with dP, vortex,
and magnetic flow measurement can be over-
come by employing new technologies.
Figure 1: With dP flow
Measuring dP flow measurement, the flowmeter
Measuring flow via differential pressure is the measures the pressure dif-
most common flow measurement technique and ferential created by an orifice
has been proven in use for decades. A dP flow- plate from which the meter
meter is a cost-effective way to measure volu- will calculate volumetric flow.
metric flow, especially in applications with large All images courtesy: Rose-
line sizestypically 8 in. dia. and more, such as mount, a division of Emerson
those found in water feed and discharge lines. Process Management
Unlike other technologies, dP flow measurement
can be used with conductive and nonconductive
fluids allowing it to be used with a wide range of
gases and liquids.
The primary element in a dP flowmeter creates
a pressure drop by introducing a restriction in a MORE
pipe. This pressure drop is then measured by the ADVICE
second componenta dP transmitter, which sends
the readings to the control system. Depending on KEY CONCEPTS
the exact nature of the dP flowmeter, the remain- Select the appropriate flow tech-
nology for the application.
ing components may include impulse piping and
Evaluate flowmeter first, installa-
the connectors routing the upstream and down- tion second, and finally lifecycle costs.
stream pressures to the transmitter.
Consider the advantages and risks
By creating an engineered restriction in a pipe, of employing wireless flow measure-
typically an orifice plate, a Pitot tube (a Pitot tube ment technology.
measures the difference between the static pres- GO ONLINE
sure and the flowing pressure of the media in the Link to more online resources,
pipe), or an Annubar (an Annubar is an averag- flow measurement links, and related
ing Pitot tube that takes multiple samples across content in January 2016 at
www.controleng.com/archives.
a section of a pipe), Bernoullis equation can be
CONSIDER THIS
used to calculate flow rate because the square root When evaluating flow measurement
of the pressure drop across the restriction is pro- choices understand the differences
portional to the flow rate. among technologies.
CONTROL ENGINEERING JANUARY 2016 | 29
PROCESS flow measurement
Figure 2: This direct-
mount dP flowmeter
eliminates the need for
impulse lines, reducing
installation cost and main-
tenance.
Figure 3: In a vortex
meter, the vortices cre-
ated by the shedder bar
resonate at a frequency
proportional to the veloc-
ity of the fluid flow in
the pipe.
30 | JANUARY 2016 CONTROL ENGINEERING
A dP flow measurement has a wide range
of applicability. However, challenges may arise
depending on the particular application, the
chief among them being wet-leg issues. Wet
leg is the term used to describe the impulse
line connection between the dP transmitter and
the primary flow sensing element. A gasair,
for examplecan get trapped in a wet leg and
impact flow measurement accuracy. In addition,
wet legs can become clogged and may freeze in
cold conditions.
Existing technology allows an integrally
mounted pressure transmitter to connect direct-
ly to the primary flow element, eliminating the
impulse line and its wet-leg issues. These assem-
blies can be installed easily and quickly because
no impulse lines are required. In addition, main-
tenance costs are decreased because leak points
are reduced.
Another dP flow measurement issue can be
introduced by traditional orifice plates because
they require significant straight runs of pipe to
reduce flow disturbancesup to 44 pipe diam-
eters upstream of straight-run pipe and seven
diameters downstream. For a 12-in. dia. pipe,
44 ft of straight pipe run would be required
upstream, and 7 ft would be required
downstream.
In many cases, bends in the pip-
ing within these distance limitations can
cause measurement inaccuracy with tra-
ditional orifice plates. In these
instances, a conditioning orifice
plate can be used. A condition-
ing orifice plate requires only
two pipe diameters upstream
and downstream of the orifice
plate of straight pipe run, which
greatly increases the num-
ber of applications for dP flow
measurement.
Vortex meters
Vortex meters measure fluid flow according
to the Von Karman effect, where a fluid striking
an obstruction (shedder bar) creates alternat-
ing vortices, or low-pressure areas, behind the
bar at a frequency proportional to the velocity of
the fluid. The measured frequency is converted
to flow velocity, which is then converted to the
volumetric flow rate. Industrial vortex meters
were introduced in 1968 and have been success-
fully used to measure the flow of steam, gases,
and clean liquids. As with all flow measurement
technologies, there are challenges and resolu-
tions when applying vortex meters.
Typical vortex designs have small free spac-
es or crevices around sensors or shedder bars
Figure 4: These four vortex meters are
measuring steam flow in an enhanced oil
recovery field.
to create the movement needed to create vor-
tices. Coating or particulate matter in the fluid
can clog the crevices and inhibit sensor move-
ment resulting in inaccurate flow measurement.
All-cast vortex meters eliminate the need for
free sensor movement and are thus insensitive
to coating and clogging. Therefore, they can be
used to reliably measure flows of dirty fluids that
would plug traditional vortex sensors.
A minimum flow ratereferred to as the
low-flow cutoff is required to establish
the vortices. Flow rates at the lower end of the
desired measurement range may fall below this
minimum and thus cannot be measured, fre-
quently requiring the flowmeter and piping size
to be reduced to increase velocity.
Reducer vortex meters have concentric reduc-
ers designed and built into the meter body that
enable measurement of lower flow rates without
expensive and disruptive process piping modifi-
cations. Factory calibration of the reducer vortex
meter ensures accuracy and eliminates the need
for additional upstream and downstream piping
in the field.
In some cases, mass flow is the preferred
measurement instead of volumetric flow. For
example, in process steam efficiency calcula-
tions, the preferred unit of measure for saturated
steam flow is lb/hr, as opposed to a volumet-
ric rate. Pressure or temperature compensation
can be used to enable a vortex meter to measure
the mass flow of fluids. Integrating these com-
pensating measurements into the meter reduces
installed cost and complexity.
Vortex meters are often used to measure crit-
ical flows of aggressive chemicals. Tradition-
al sensor designs provide potential leak paths,
possibly allowing process fluids to escape from
www.controleng.com
the line. These designs also cannot be serviced
without shutting down the process and poten-
tially exposing workers to process chemicals. For
measuring these critical flows, all-cast meters
with isolated sensors eliminate common leak
points and can be safely serviced under process
conditions.
Mag meters
Mag meters operate on the principle of Far-
adays law of electromagnetic induction, where
a voltage is developed when a conductive fluid
is passed through a magnetic field. The voltage
developed is proportional to the strength of the
magnetic field, the length of the conductor, and
the velocity of the conductor described by the
equation:
E = KBLV
Where:
E = voltage measured at the electrode
K = the meter constant
B = the field density (strength of the
magnetic field)
L = the length of the conductor (length of
the conductive path between electrodes)
V = the velocity of the conductor
(conductive fluid).
Flow velocity can thus be obtained, and by
extension, volumetric flow.
Mag meters were introduced in 1952 and
are used to measure the flow velocity of a vast
number of conductive liquids. Because they
introduce no obstructions in the fluid stream,
they avoid many issues found with insertion
meters, such as pressure drop, product shear,
or wear and tear on the meter from the flow-
ing fluid.
Mag meters can measure abrasive and high-
solid slurries. In addition, wetted surfaces (liner
and electrodes) can be selected for compatibil-
ity with chemically aggressive or abrasive fluids.
The wetted surfaces of the meter can be selected
to match the characteristics of the process fluid,
extending meter life.
Advances in material technologies and instal-
lation techniques can further improve reliabili-
ty and extend the life of the meter. Using meters
that feature all-welded design and isolated com-
partments that protect against moisture and con-
tamination can improve reliability.
www.controleng.com
Liners with increased
temperature resistance,
reduced permeation, and
resistance to oil in appli-
cations, such as produced
water measurement in
oil production applica-
tions, extend service life,
as do options, such as lin-
ing protectors and hard-
ened materials to protect
against abrasive wear.
Installation practices can
manage velocities to fur-
ther reduce abrasion or to
manage temperature gra-
dients and reduce the rate
of permeation. Figure 5: The sensing
Quality and regulatory requirements often electrodes on this mag
require periodic confirmation that the meters meter measure the mag-
continue to measure flow accurately. This typi- netic field produced by
cally requires removing the meter from the line the flow of conductive
and confirming accuracy at a flow lab or bring- fluid through the meter.
ing additional equipment to the field so the cali-
bration can be verified with the meter offline.
Smart meter verification is an accepted method
where the technology is built into the flowme-
ter so it can verify performance without tak-
ing the flowmeter offline and without special
equipment.
Smart meter verification validates the hard-
ware, software, coils, electrodes, and intercon- Modern noise
necting wiring. Verification can run continuously
or can be initialized through the local operator mitigation
interface or via a remote software command.
There is typically a significant reduction in technologies
downtime due to the elimination of calibration
verification as well as errors associated with dis- can be used
connecting and reconnecting functional meters.
In addition, smart meter verification can simply to provide
and easily confirm initial installation, providing
instant feedback that the installed meter is func- a more
tioning as intended.
Fluids often contain particulates that can accurate and
cause noise that interferes with the flow mea-
surement. Examples include mining slurries, responsive
pulp and paper mill slurries, and produced
water with high levels of sand carryover. Par- flow signal.
ticulates striking the electrode cause high lev-
els of noise (similar to the effect of tapping on
a microphone), which can result in low signal-
to-noise ratios, reduced accuracy, and poor loop
performance.
Traditional means of dealing with high pro-
cess noise involves the addition of damping,
which can reduce loop response to unaccept-
able levels. Modern noise mitigation technol-
ogies can be used to provide a more accurate
CONTROL ENGINEERING JANUARY 2016 | 31
 PROCESS flow measurement

and responsive flow signal. Wireless devices connect to a wireless gate-

Figure 6: Mag meters can
be used to measure flow in
very large pipes, a feature
employed as an advantage
in this application.
These technologies include
diagnostics that dynamical-
ly monitor signal-to-noise
ratios, adjustable coil drive
frequencies to move to a
less noisy frequency, and
high signal mag meters with
increased signal power.
Wireless options
Mag, vortex, and dP
meters are available as wire-
less devices. The transmit-
ters in dP meters are available in versions with
integral wireless, while mag and vortex meters
are available with adapters to convert their out-
puts to a wireless signal at the transmitter. The
primary value of wireless is delivered with either
configuration.
Wireless installations transmit process data
and diagnostic information wirelessly, elim-
inating the need to run signal wiring to the
I/O panels. Eliminating signal wiring allows a
much quicker and less expensive installation as
theres no need to run wires, and it also reduces
maintenance.
way that can be located in close proximity and
connected to the control system via hard wiring.
Wireless technology also eliminates the need for
additional analog input points at the control sys-
tem to accept the signal wiring from the devic-
es, which can be very expensive, particularly if a
new analog input card needs to be added.
Closing the loop
Mag, vortex, and dP flowmeters are the lead-
ing technologies used to measure volumetric flow
or flow velocity. Each technology has its place, and
each has its challenges. The first decision is the
selection of the right flow technology for the appli-
cationa task where a trusted supplier or system
integrator can be enlisted to provide assistance.
The next task is to ensure the proper meter is
specified for the application, including required
features and options to overcome the flow measure-
ment challenges inherent to the application. ce
Wally Baker is pressure content marketing manag-
er, and Rob Pozarski is senior industry manager,
both with Emerson Process Management. Edited
by Jack Smith, content manager, CFE Media,
Control Engineering, jsmith@cfemedia.com.

2015 System Integration

Turning research into insights makes for better business decisions
The 2015 System Integration study was conducted by Control Engineering
to better understand system integration of devices and systems as applied
to controls, automation, and instrumentation from the perspectives of the
system integrator and the engineering hiring the system integrator.

According to the study forty-six percent of respondents firms are

involved in system integration projects valued at $100,000 or more.
While two-thirds of respondents firms have integrated and/or plan
to integrate software; human-machine interface hardware/equipment,
operator interface, etc.; and programmable logic controllers or
programmable action controllers.

Access the full Control Engineering 2015 System Integration

report with additional findings and insights.
www.controleng.com/2015SystemIntegration
ROUNDTABLE system integration

System integrators
plan, evolve for the future
Get tips on recruiting and retaining young talent to overcome the skilled worker shortage facing
manufacturing and on present and future system-integration challenges from CFE Medias interviews
of three representatives from the 2016 System Integrators of the Year. See video.

A
utomation and system integra-
tion is constantly evolving. There
are developments like the Indus-
trial Internet of Things (IIoT) and
Industrie 4.0 that will have a major
impact on how data is gathered as well as how
operations are conducted. These developments
dont mean anything without the right people
in the company. This is a challenge facing many
manufacturers and system integrators, and it
will remain an issue for years to come.
CFE Media interviewed three representa-
tives from the 2016 System Integrator of the Year
firmsTim Matheny, president of ECS Solu-
tions; Michael Gurney, president of Concept Sys-
tems; and David Blaida, executive vice president of System integrators offer their insights for the future of manufacturing in a video
Matrix Technologiesfor what they expect. from Control Engineering and Plant Engineering. CFE Medias Bob Vavra is on the
left. From left-center are the representatives of the firms named as the 2016 System
CFE Media: What are the biggest challenges Integrators of the Year: Tim Matheny, president of ECS Solutions, Michael Gurney,
facing your companies and the system integra- president of Concept Systems, and David Blaida, executive vice president of Matrix
tion industry? Technologies. Courtesy: CFE Media video

Matheny: I think the big challenge is as com-
panies are converging, the idea that control systems
that we have traditionally done for years for infor-
mation technology, and marrying those systems
together in a way that the control systems are deliv-
ering business value and measurable business.
Gurney: One of the challenges I see with sys-
tem integration is the pace in which technology
is evolving and staying on top of it. A lot of these
technologies arent ready for primetime. Just vet-
ting them out and when is the right time to deploy
them in an industrial environment so that they can
perform on a reliable basis for our customers.
Blaida: One of the challenges that we see
as a company and part of our industry specifi-
cally is recruiting and retaining quality talent.
The biggest thing that we offer as a company is
our people and their knowledge of the technol-
ogy, the challenges that we face and our custom-
ers face. Getting the right people, keeping them
interested, keeping them plugged into the com-
pany thats the most important thing that we face.
CFE Media: How are you finding and retain-
ing skilled workers, which is more of an an issue
for manufacturers as older workers retire?
Gurney: Its about working with universities
and targeting young folks. When we go to them
were pitching to them the variety of the technol-
ogy out there and the variety of industries where
you can interpret these technologies. And for us its
about getting them on board. Training and mentor-
ing, part of our culture, is the key to keeping them.
Blaida: As weve grown, its harder to find the
most seasoned technical folks. You really need to
grow them, and you really need to start at the uni-
versity level. We have a strong co-op program, and
we bring them on board. We have spent a lot of
MORE
ADVICE
KEY CONCEPTS
Technology is evolving, and
seamless integration is a challenge
for many.
Recruiting young people into
STEM careers is important, but
training and integrating them into a
companys culture is also vital.
The state of the oil and gas industry
could have an impact on manufactur-
ing; overall outlook remains positive.
CONSIDER THIS
What challenges do you see for
system integrators and manufacturers
in 2016?
GO ONLINE
Learn more about 2016 System
Integrator of the Year winners
at www.controleng.com/SIY.

www.controleng.com CONTROL ENGINEERING JANUARY 2016 | 33

 system integration

Relax, tomorrow has already been tested.

time and energy to invest in training pro-
Say goodbye to hardwiring with grams for our people and a full on-board-
HARTING connectors. ing process is very important so that they
become integrated, ...work with the folks
with more experience. Training includes
culture, projects, and then technology, last,
he said.

Matheny: ECS started, probably 15

years ago, partnering with local education-
al institutions to work with their depart-
ments, even to define curriculum.... We
stayed engaged with them and actively
worked to offer internships and oppor-
tunities to local university students.

CFE Media: Manufacturing optimism

remains, but there are challenges. Please
share some advice.

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Blaida: The challenge that weve seen
in the past 6 to 12 months is that the proj-
ects have become smaller, and our custom-
ers are not investing in the huge projects
they were shortly after the recession
ended. We really gotta focus on custom-
er service and make sure we deliver things
on time, on budget, and making sure we
meet customer expectations so they want
to come back to us next time.
7/23/2015 4:32:46 PM

Matheny: The bright spot for us is at

TMPS series for energy ECS we continue to develop ourselves as
efficiency in low power mode. more of a national batch process integra-
tor instead of the roots that we came from
AC/DC power modules as a local integrator, doing anything for
3 to 5 Watt for PCB mount. anybody close by, and that focus is really
driving a lot of change in our company. I
always get worried in an election year. We
just have to wait and see. Overall we think
its going to be a very good year.

Gurney: Oil and gas has ramifications

in a lot of different industries. It hits us
pretty hard in the recycling industry ... so
recycling is not as attractive. From a bright
spot, I didnt anticipate continued steady
growth, and I think a lot of our manufac-
turing customers learned some lessons in
the past, and they are being smart about
how they spend money so theyre really
zeroing in on those projects that have a
strong return on investment. ce
VIDEO and articles: Link to more
from each System Integrator of the Year at
www.controleng.com/SIY.

Reliable. Available. Now. tracopower.com Edited by Chris Vavra, production editor,

Control Engineering, cvavra@cfemedia.com.

input #15 at www.controleng.com/information 34 | JANUARY 2016 CONTROL ENGINEERING

INSIDE PROCESS temperature control
Applying heat exchanger
control strategies
Integrating control schemes, such as feedback, cascade, and feedforward
techniques, can satisfy the control requirements of even highly challenging
heat exchanger temperature control applications.
H
eat exchangers transfer thermal ener-
gy between fluids. Although heat trans-
fer is typically efficient, controlling the
temperature of the fluid being heated at
a specific and stable setpoint can be challenging.
However, these challenges can be overcome by
understanding heat exchanger control schemes
implemented in industry.
Heat exchanger, at a glance
By far, the shell-and-tube is the most com-
mon type of heat exchanger used in petrochemi-
cal industries because it is suitable for low and
high pressure applications (see Figure 1). It con-
sists of an outer shell with a bundle of tubes
inside. The tubes are oriented in a straight or in
a U shape. One fluid runs through the tubes,
and another fluid flows through the shell sur-
rounding the tubes to transfer heat between
the two fluids (see Figure 2). The set of tubes is
known as a tube bundle.
Heat is transferred from one fluid to the other
through the walls of the tubes.
Heat is transferred from the tube fluid to shell
fluid to remove heat, or from the shell fluid to
the tube fluid to heat the material inside. Fluids
can be liquids or gases on either the shell or the
tube side. To transfer heat efficiently, many tubes
are used, which increases the heat-transfer sur-
face area between the two fluids.
Control objective
To develop a comprehensive control strate-
gy for any control loop, its important to identify
the process variable of interestcalled the con-
trolled variable, the manipulated variable, and
the different disturbance variables that directly
affect the controlled variable.
Consider the heat exchanger shown in Figure
3. The shell side fluid is the process fluid that must
be heated to a certain temperature setpoint. The
resulting temperature is measured at the outlet of
the heat exchanger T1Out (controlled variable).
Heating is achieved by passing steam through
the tube side. The more steam passing through
www.controleng.com
the tubes, the more heat is transferred to the MORE
process fluid, and vice versa. Control of the ADVICE
steam flow F2 (manipulated variable) is achieved
KEY CONCEPTS
by throttling a modulating valve installed on the Understand the control tech-
steam inlet side. niquesfeedback, cascade, feedfor-
Three major disturbances can affect the pro- ward, and PIDassociated with heat
cess fluid outlet temperature: exchanger temperature control.
Evaluate how process variable
 Changes in process fluid flow rate, F1 upsets and corrections affect control
performance.
 Changes in process fluid inlet Consider the advantages and risks
of integrating these control tech-
temperature, T1In niques to optimize heat exchanger
temperature control.
 Changes in steam pressure, causing GO ONLINE
a change in steam flow rate, F2. Link to additional online resources,
heat exchangers, temperature control,
The control objective is to maintain process and related content at
www.controleng.com/archives, under
fluid outlet temperature T1Out at the desired set- January 2016.
pointregardless of disturbancesby manipu- CONSIDER THIS
lating the steam flow rate F2. What processes in your facility
could benefit from these techniques?
Feedback control
In the feedback control scheme, the pro-
cess variable, T1Out, is measured and applied to
a proportional-integral-derivative (PID)-based
feedback temperature controller (fbTC), which
compares the process variable with the desired
temperature setpoint and in turn calculates and
generates the control action required to open or
close the steam control valve (see Figure 4).
The most important advantage of the feed-
Typical shell-and-tube heat exchanger
Figure 1: The shell-and-tube is the most common type of heat exchanger
used in petrochemical industries because of its suitability for low- and high-
pressure applications. All images courtesy: Shady Yehia, The Control Blog
CONTROL ENGINEERING JANUARY 2016 | P1
 INSIDE PROCESS temperature control
Figure 2: A cross section
of a shell-and-tube heat
exchanger reveals the tube
bundles inside. One fluid
runs through the tubes
while another fluid flows
through the shell surround-
ing the tubes to transfer
heat between the two
fluids.
Steam in
Steam out
Figure 3: Heat exchanger instruments measure and
manipulate flow rates and temperatures.
T1Out setpoint
Steam in
Steam out
Figure 4: Feedback con-
trol applies a temperature
measurement to a con-
troller, which provides the
control action to operate a
steam control valve.
P2 | JANUARY 2016 CONTROL ENGINEERING
Steam
inlet Process fluid inlet
Steam
outlet
Process fluid outlet
back control scheme the outlet temperature matches the setpoint, and
is that regardless the controller output of fbTC is constant. A sud-
of the disturbance den increase in steam pressure will cause steam
Process fluid in
source, the control- flow rate F2 to ramp up (see Figure 5). This will
ler will take correc- cause a gradual change in the controlled vari-
tive action. Employing able. Without the flow control loop, fbTC will
feedback control not take corrective action until the outlet tem-
requires very lit- perature is already affected.
tle knowledge of By implementing the cascade strategy, the
Process fluid out the process. There- feedback flow control loop fbFC will adjust the
fore, a process model valve position immediately when the steam
is not necessary to flow rate has changed to bring the flow back to
set up and tune the the value of the previous steady-state condition
feedback scheme, (because the flow setpoint given by the tempera-
although it would be ture controller didnt change as the outlet temper-
an advantage. ature did not yet change), preventing a change in
The major disad- the outlet temperature before it happens.
vantage of feedback Note that the flow control loop must be tuned
control is its incapa- to run much faster than the temperature con-
Process fluid in bility to respond to trol loop, therefore cancelling the effect of flow
disturbanceseven variance before it affects the process fluid outlet
major onesuntil the temperature.
controlled variable is
already affected. If too Feedforward control
many disturbances Unlike feedback control, feedforward takes
occur with significant a corrective action when a disturbance occurs.
Process fluid out
magnitude, they can Feedforward control doesnt see the process vari-
create unrecoverable able. It sees only the disturbances and responds
process instability. to them as they occur. This enables a feedfor-
ward controller to quickly and directly compen-
Cascade control sate for the effect of a disturbance (see Figure 6).
In the cascade control scheme, instead of To implement feedforward control, an under-
feeding the output of the PID temperature con- standing of the process model and the direct
troller directly to the control valve, it is fed as relationship between disturbances and the pro-
a setpoint to a feedback PID-based, steam-flow cess variables is necessary.
controller (fbFC). This second loop is respon- For heat exchangers, a derivation from the
sible for ensuring the flow rate of the steam steady-state model will lead to the following
doesnt change due to uncontrollable fac- equation, which determines the amount of steam
tors, such as steam pressure changes or valve flow required:
problems.
To understand how this works, consider that F2sp = F1 (T1 OUTs p T1IN) (Cp/H)
the heat exchanger is in steady-state operation, Where:
www.controleng.com
input #16 at www.controleng.com/information
INSIDE PROCESS heat exchanger temperature control

measured disturbance
T1Out setpoint

Cp = process fluid specific heat

(known)

H = latent heat of vaporization for

steam (known).
Process fluid in
Steam in Applying this equation to calculate the
required steam flow rate is sufficient to cancel
the effects of changes in the process fluid flow
rate and temperature. In a perfect world with few
enhancements to the process model, this feed-
forward controller is enough to perfectly con-
trol the process. Unfortunately, its not a perfect
Steam out Process fluid out world.
The obvious advantage of using feedforward
control is that it takes corrective action before
Figure 5: Cascade the process is upset. A disadvantage is that it
control can handle F2sp = steam flow rate calculated set- mandates a high initial capital cost because every
steam pressure and point to be applied to fbFC disturbance must be measured, increasing the
valve related issues. number of instruments and the associated engi-
F1 = process fluid flow rate measured neering costs.
disturbance In addition, this approach requires deeper
knowledge of the process. Its not always realis-
T1OUT sp = process fluid temperature set- tic to depend on feedforward control only with-
point at the heat exchanger outlet out taking into account the measured process
T1IN = process fluid inlet temperature variable.

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input #18 at www.controleng.com/information
 INSIDE PROCESS temperature control

Integrated approach  A feedforward loop will handle major

T1Out setpoint An integrated approach that disturbances in the process fluid
uses feedback, feedforward,
and cascade control is shown  A cascaded-flow control loop will
in Figure 7. This approach is handle issues related to steam pressure
more than capable of accom- and valve problems
Process fluid in modating heat exchanger con-
Steam in
trol requirements:  A feedback loop will handle
everything else.
Figure 6: Feedforward con-
trol deals with major distur- Combining the three techniques to optimize
bances in the process fluid heat exchanger temperature control is necessary
Steam out Process fluid out
because it is not influenced to minimize process variance, maximize product
by the process variable. quality, and ensure energy efficiency in petro-
chemical industries. ce
T1Out setpoint
Figure 7: Inte-
grating feedback, Shady Yehia is the founder and author of
feedforward, and The Control Blog (thecontrolblog.com) and is
cascade heat the instrumentation, control, and automation
exchanger temper- Process fluid in
proposals and engineering manager in a pro-
Steam in
ature control tech- cess technology integration company based in
niques minimize Qatar and operating in the EMEA region.
process variance, The Control Blog is a CFE Media content part-
maximize product ner. Edited by Jack Smith, content manager,
quality, and ensure CFE Media, Control Engineering,
Steam out Process fluid out
energy efficiency. jsmith@cfemedia.com.

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INSIDE PROCESS moisture measurement

When moisture matters

Learn why moisture content can affect the quality and cost of the final
product and how a near infrared (NIR) moisture meter can help. Figure 1: NIR measurement

M
oisture content can affect the quality
and cost of the final product (see Fig-
ure 1). Therefore moisture consisten-
cy can reinforce customers loyalty to
a particular brand of end product manufactured.
A company might need an NIR moisture meter if:
 The application involves coated or uncoated
moving webs, flat-belt, vibratory, screw conveyors,
or extensive time-consuming laboratory testing.
 The process requires noncontact moisture
measurement online and in real time.
 The process needs an instrument that will nei-
ther heat nor chemically treat the measured prod-
uct and in fact would not contact the product at all.
 The company wants data that are continu-
ous, instantaneous, and nondestructive, with out-
put signals that can be used to control production
processes.
 The company wants to increase energy effi-
ciency by not over-drying the process material.
can detect moisture content
 The process is characterized by any of the fol- that can affect the quality and
lowing: powders, granular, chips, chunks, flakes, cost of the final product. All
sheets, webs, films, coatings, or are otherwise fair- images courtesy: Cross Com-
ly thin and homogenous in moisture distribution. pany Integrated Systems
 The industry is any of the following: plastics
and composites, R&D laboratories, textiles, paper,
MORE
agriculture, food processing, pharmaceuticals,
chemicals, lumber, or anything else where mois- ADVICE
ture content affects the final product. KEY CONCEPTS
Understand how moisture content
How does NIR work? can affect quality and cost.
The NIR-measurement process can provide the Learn about NIR measurement.
reliable and repeatable data needed to discover the Consider criticality of accurate
magic number of moisture content in an industri- process data.
al process. When additional heat or chemicals are GO ONLINE
Link to resources on moisture
introduced into the process environment, the pro- measurement, infrared technology, at
cess material can be negatively affected. To avoid www.controleng.com/archives, under
altering the process characteristics, NIR technology January 2016.
uses a fixed-position halogen source lamp aimed CONSIDER THIS
at the material being evaluated (see Figure 2). The How can historian data help?

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input #20 at www.controleng.com/information

INSIDE PROCESS moisture measurement

Figure 2: NIR lamp generates a full-spectrum, white- onto a lead-sulfide detector cell. The meter
technology uses light frequency. can calculate the amount of moisture in
a fixed-position Some of the energy in this light is at a the product by comparing the amount of
halogen source frequency that causes water molecules to reflected energy stored in the cell to the
lamp aimed at the vibrate or resonate. The water molecules amount generated by the source light.
material being eval- in the product will absorb a percentage of Measurement accuracy is improved
uated. The lamp the source energy and reduce the strength with special filters that compensate for
generates a full- of the reflected light. The NIRs internal variations in ambient light, color, prod-
spectrum, white- fixed-position lenses then pass the reflect- uct distance to sensor, dirty optics, aging
light frequency. ed light through a 1.94 bandpass filter source lamp, and other factors.

Data, data, data

Having reliable data reinforces deci-
sions. Data capabilities of advanced NIR
systems include: Panel touchscreen PCs
display moisture content in easily read
numbers; automatic reflectance gain con-
trol; current output (4 to 20 mA), scaled
and isolated; isolated opto-coupler tran-
sistor to signal loss of product; scaling and
linearization via serial data port; software
window for product calibration; and soft-
ware window displays chart of machine
direction moisture profile.
The collected data can be sent to a
long-term historian for further reporting
and analysis by engineering teams (see
Figure 3). Creating this accurate data in
the process can help pinpoint the moisture
content ranges associated with quality. If
the company uses the data to establish a
moisture scale of too much, too little, and
just right, users can make decisions about
their processes that will ensure that mois-
HMI Solutions for Every Machine ture stays within acceptable ranges.

Energy savings
A particular area that realizes pro-
duction savings is in the energy used for
Maple Systems HMIs offer quality, drying products. This is achieved by asso-
affordable solutions for any industry. ciating the acceptable moisture range
with ideal dryer temperature to establish
the length of time the dryers operate. As
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Ethernet + Serial Ports tional cost of over-drying are eliminated.
Modbus Gateway Results of this consistency will likely be
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Data Logging
in the marketplacefactors that affect the
Alarm Management final price for customers and possibly pro-
Email Notification vide a competitive edge. ce
Quality
Enhanced Security
Brendan Quigley graduated from Millsaps
College in 2003 and joined Cross Compa-
ny Integrated Systems in early 2012 as an
What can we help you control? inside sales representative. Cross Company
Integrated Systems Group is a CFE Media
content partner and a CSIA member as of
Your Industrial Control Solution Sep. 6, 2015. Edited by Jack Smith, content
www.maplesystems.com | 425.745.3229
manager, CFE Media, Control Engineer-
ing, jsmith@cfemedia.com.
input #21 at www.controleng.com/information P8 | JANUARY 2016 CONTROL ENGINEERING
HANNOVER MESSE
25 29 April 2016
Hannover Germany
The USA will be highlighted at the worlds largest industrial
technology trade fair. To explore opportunities at HANNOVER
MESSE, call +1 (773) 796-4250 or visit www.hannovermesse.de.

Sign up for free tickets: www.hannovermesse.events/cfemedia

Get new technology first

input #22 at www.controleng.com/information

 U.S. business leaders love it!

Phoenix Contact How was Hannover Messe?

Tribby Warfield I was able to see key suppliers
and see the latest technology in
a world-class showcase.

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input #23 at www.controleng.com/information
THE ROAD TO
HANNOVER MESSE2016
A starting point for global exposure
Hannover Messe is a big event for a small U.S. manufacturer.
K
irk Shaffers second impression of Han-
nover Messe in 2012 was the sheer size
of the booths. I remember going for
the first time, walking into the hall,
and saying, Some of these booths are bigger
than our entire office, said Shaffer, the chief
marketing officer for Bloomfield, Colo.-based
AirSquared, a manufacturer of specialty scroll
compressors and recirculation pumps.
His first impression of Hannover Messe was
formed months earlier when fair officials approached him at a
U.S. trade event and suggested their technology would be an
excellent fit at Hannovers Hydrogen+Fuel Cells group exhibit.
Its a massive show, but the area they specifically were looking
at was a trade show in a trade show, Shaffer said. It was in the
energy pavilion and then there was fuel cell area inside energy
pavilion. We started talking with them logistically about what
is involved with exhibiting.
AirSquared will be back this spring at Hannover Messe 2016,
which takes place April 23-27 in Hannover, Germany. While
hundreds of U.S. companies are expected to exhibit during the
AirSquared officials found value
in expanding their global brand
by attending Hannover Messe.
Courtesy: AirSquared
Partner Country year for the United States,
AirSquareds annual journey to Germany is
more about building on the success the com-
pany has found in exhibiting abroad.
Help for new attendees
The 2016 Partner Country status for the U.S.
has created unique opportunities for American
manufacturers looking to establish a global
presence. The U.S. visibility at Hannover Messe
means additional exposure and prime location for U.S. com-
panies, institutions, and economic development organizations,
particularly those exhibiting in the U.S. Pavilions, said Daniel
Gaines, senior international trade specialist for the U.S. Com-
mercial Service, a part of the Commerce Department.
It means that manufacturers of any size will stand out promi-
nently in a trade show that attracts more than 200,000 visitors,
Gaines said.
At Hannover in 2016, new services will include:
 Pre-show educational webinars to help companies pre-
pare for the event;
CONTROL ENGINEERING JANUARY 2016 | 45
 Visit Beckhoff at Hannover Messe 2016
in Hall 9, Booth F06!

input #24 at www.controleng.com/information

THE ROAD TO NEW
HANNOVER MESSE2016
Single-channel
n Pre-show promotions
to potential overseas
partners, helping
eBreaker
U.S. exhibitors get
maximum exposure to
potential buyers, part-
ners, and investors at
the show;
n On-site executive mar-
keting counseling with
commercial experts
from U.S. Embassies AirSquared chief marketing officer Kirk Shaffer
from across the globe, (center) called Hannover Messe a perfect starting
helping U.S. exhibitors point for people who feel they arent doing enough
create custom strategies overseas. Courtesy: AirSquared
for approaching key
global markets, and were also a small company. Being able to

Make it EasyB
n Post-show follow-up support to expand our presence overseas is a huge
ensure U.S. exhibitors know the initiative, and we had to figure out the
next steps to take with new show right way to go about it. From that first
connections. show, we had great results. Really early on,
we knew wed hit the jackpot.
State economic development organiza- Now the process for AirSquared is to
tions also will be bringing teams to Han- continue to build on those first relation-
nover. That effort has expanded over the ships formed four years ago. Shaffer said,
past several years. Around 2005, a handful In February, you start e-mailing people
of state teams were on the floor at Han- that youre going to be there, and before
nover, Gaines said. In 2015, more than you know it, you have a decent number
30 states were represented at Hannover, of meetings lined up before you get there.
including an appearance from Wisconsin Now were meeting face-to-face with peo-
Gov. Scott Walker. ple weve already dealt with in the past.
But resources are available year-round Shaffer has found that the investment
for companies seeking expansion any- of time and capital has helped AirSquared
where in the world. Helping U.S. manufac- establish its technology and company
turers stand out is part of the Commercial 5,000 miles from headquarters.
Services overall mission. The trade shows (in Hannover) tend
The U.S. Commercial Service manages to be a lot more formal, with a lot higher
more than 100 offices across the country, level of engineers. In the U.S., you get a
affording manufacturers the opportunity variety of people attending, Shaffer said.
of having a locally based trade professional We found that not only is there more traf- ADVANCED
to help locate the right resources, pro- fic [at Hannover], but you do leave the MANUFACTURING
grams, and avenues that companies can show with a lot of contacts.
leverage to extend their reach and export
to more markets. The Commercial Ser- Starting point for expansion
24V PROTECTED
CONNECTED
COMMUNICATED

vice Website offers help www.export.gov. With a minimal efforta week out of
the yearyou can connect with Europe New EasyB single-channel eBreakers
Standing out in a crowd and, really, all over the world. Its a perfect installed side-by-side, easy to set up to
AirSquared received a grant from the starting point for people who feel they establish a controlled 24 Vdc system.
state of Colorado to attend its first Han- arent doing enough overseas, said Shaf-
nover Messe. Even with the assistance fer. Youre not just going to walk away
Hall 13,
from both sides of the Atlantic, the chal- with new contacts overseas, youre going
stand C34
lenge still was to make an impression and to meet people you want to partner with.
build partnerships. If any small company doesnt know how
I think every company is a little to go about it and thinks product needs to
unique, Shaffer said. We have a unique go globally, this is your starting point. ce
technology; there arent many compa- Bob Vavra is content manager, Plant input #25 at www.controleng.com/information
nies making a comparable product, and Engineering, bvavra@cfemedia.com.

CONTROL ENGINEERING JANUARY 2016 | 47 blockusa.com

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48 | MONTH 2016
JANUARY 2016CONTROL
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CONTROL ENGINEERINGJANUARY
ENGINEERING MONTH 2016 | 49
 T he voice of the engineering community
speaks loud and clear in the following pages
featuring corporate profiles of those companies
participating in the Executive Voice program
presented by Control Engineering magazine.

Our thanks to the following participants:

Allied Moulded Products, Inc.

Beckhoff
Dataforth
Emerson Process Management
EPLAN Software & Services
EZAutomation
Harting
Kepware Technologies
Kyland Corporation
Maple
Moxa
SEW Eurodrive

W here are automation
control products being used
today? Of course when we consider
the typical application of a program-
mable logic controller (PLC) and
human machine interface (HMI),
we think of automating an assembly
line or monitoring plant efficiency.
The automotive, packaging, pharma-
ceutical, food & beverage, textile, oil
& gas, and other process industries
have been using automation controls
for decades now.
But where is automation expanding
into recently? With PLCs and HMIs
Five years ago, nobody really considered being able to
control their machine from half way across the world.
getting smaller, easier to program
and more cost effective, automation
has expanded into all types of
applications in both the industrial
and consumer sectors.
Industrial examples include auto-
mating smaller auxiliary machinery
where before simple push buttons
and relays were used due to cost
constraints. Consumer based
applications include small table-top
testing machines for research labs,
home automation, medical devices,
green-house watering, coffee
dispensers, cigarette rollers, or even
crazy applications such as under-
water dog treadmill training!
In order to accommodate the
expanding applications of
ADVERTISEMENT
automation control products,
manufacturers such as Allen-Bradley,
Siemens, Mitsubishi, and
Vikram
EZAutomation must keep up with Kumar
market demands that require smaller, President,
network capable and cost effective EZAutomation
controllers. For example, automation
users not only want to automate their
machines now, but also have the need
to remotely access their system using
their iPhones and Androids.
application with its unique data
Five years ago, nobody really signature feature for real-time
considered being able to control their machine diagnostics or remote
machine from half way across the marketing on the HMI, the
world! Now its almost the norm to EZAutomation products are now
be able to monitor or control ones used in all types of consumer and
home appliances or do basic trouble- industrial applications.
shooting of a customers machine
hundreds of miles away. Keep up with the most advanced
technology in automation controls
EZAutomation has been leading such at Whats New at
technology advancements in the www.EZAutomation.net.
automation market with its PLCs
and HMIs by making them smaller, Have a unique application in mind
more network capable, and more or new idea for automation control
cost effective. products? Please email us at
sales@ezautomation.net.
For example, EZAutomation has
recently introduced its EZTouchPLC
Jr product line perfect for auxiliary
machinery and tight control spaces.
The EZTouchPLC Jr is equipped
with a 3.5 Color Touchscreen & PLC
with 28 I/O (digital & analog) and is
only 5 wide, 4 tall and 1.65 deep!
Coupled with the EZ-RMC mobile

I n the movement toward Industry
4.0 and IIoT, PC-based control
technology from Beckhoff
Automation provides the ideal toolbox
to implement the leading automation
concepts of our time.
These concepts include the Internet of
Things, cloud computing, centralized
PC-based control systems, and ever-
more connected devices via industrial
Ethernet and OPC-UA. Many users
are already integrating Beckhoff
controllers into their production
networks, enabling them to commu-
nicate with databases, perform remote
maintenance over the Internet or
request cloud-based services.
TwinCAT, Beckhoff s PC-based
control software, also permits the
secure integration of a wide range of
connected devices into the control
system such as: smartphones, tablets
and wearable technologies in the form
of smart watches and data glasses.
Feature-laden solutions
While supporting all IEC 61131-3
programming languages, a wide range
of available computer science/IT
programming tools, and other
globally-recognized standards such
as MQTT, AMQP, OPC-UA and
PackML, Beckhoff advances open and
leading edge automation solutions
that deliver high performance
and efficiency.
energy applications.
ADVERTISEMENT
Aurelio
Banda
CEO and
President,
Beckhoff
Automation
are available in multiple industry
variants, as are high performance
EtherCAT I/O solutions, servomotors
with One Cable Technology (OCT)
and gearboxes. In addition,
controllers and I/O are available
with extended operating temperature
ranges for extreme climatic
conditions such as in alternative
Durable solutions for harsh environ-
ments range from IP 65 up to IP 69K
protection to withstand cleaning
procedures typical in the food and
beverage industries, for example.

Open industrial Ethernet technology

in the form of EtherCAT and vendor
neutral solutions via OPC-UA are
available from Beckhoff to ensure
data security without restricting
connectivity. With the Power of One
controls philosophy from Beckhoff
(one PC-based controller, one
software platform and one network),
leading manufacturers and machine
builders can make great strides
toward establishing meaningful
Industry 4.0 practices while ensuring
lean automation designs and
streamlined system architectures.
With the Power of One controls philosophy from
Beckhoff, leading manufacturers and machine
builders can make great strides toward
establishing meaningful Industry 4.0 practices
This includes numerous industry-
specific technologies ideal for
increasing machine performance in
applications such as packaging,
plastics processing, metalworking,
material handling and much more. For more information:
For example, Control Panel displays www.beckhoffautomation.com

I n todays market conditions,
capital spending is tighter than
ever so it is of paramount importance
that the capital available in the process
industry is used effectively. Yet, today
we have a crisis. Most existing capital
projects fail more than 65% of
projects over a billion dollars and 35%
of projects under $500M are more
than 25% over budget or 50% late.
A study of capital projects from
Independent Project Analysis
(IPA), Inc. shows that top-quartile
performers have 54% lower costs
and 49% shorter schedules than
fourth-quartile performers for the
equivalent scope of work. Valuable
investment capital is being wasted
instead of being used on new projects
that could help organizations grow
their business and improve share-
holder value.
The path to top-quartile performance in
capital projects is right in front of us.
Now, heres the good news:
We can turn those numbers around.
The path to top-quartile performance
in capital projects is right in front of
us. New technologies and proven
methodologies can change the game
on how projects are executed.
Emerson Process Management calls
this transformative approach Project
Certainty focused on eliminating
costs, reducing complexity, and
accommodating change.
Project Certainty begins with early
engagement during Front End
Engineering and Design to define a
better project approach. Despite
traditionally accounting for
approximately 4% of a projects
investment, automation strategies
can impact cost, schedule, and
complexity beyond the a
utomation scope.
The right design strategy can eliminate
control room space requirements by
70% and can eliminate wiring from
field to control room by up to 80%.
Additionally, loop commissioning
hours, typically on the critical path,
can be reduced over 70%.
Complexity created with multiple
suppliers, engineering firms, and
stakeholders can be tackled by
decoupling hardware and software
development, facilitating global
concurrent engineering and
fabrication, and using new
technologies that provide a single
source of project data to reduce
the impact of data and
documentation changes.
Technologies like Electronic
Marshalling with CHARMs
and pervasive wireless field
instrumentation are helping
ADVERTISEMENT
Jim Nyquist
President
Systems and
Solutions,
GM Executive
Management
project teams accommodate late
project changes while reducing
impacts on schedule and cost.
Our industry needs a step-change in
how capital projects are executed
its time to think about projects
differently. We, as an automation
supplier, share responsibility with
our customers and have taken steps
forward. We must all work together to
use capital efficiently and improve the
health and well-being of our industry.
It is time for Project Certainty.
Emerson Process Management, Austin, Texas
infocentral@emersonprocess.com
1-800-833-8314
www.emersonprocess.com

W here does your search for
increased productivity
concentrate? Many companies
focus almost exclusively on the shop
floor, neglecting the engineering
department. They may be overlooking
a source of considerable productivity
enhancement by not updating their
engineering software. The age of
design automation is here, its benefits
are potentially enormous, and
will create a competitive edge for
your business.
Corporate Headquarters, in
Schaumburg, Illinois
Given the advanced technology in
the industry today, there is not one
company that can supply everything.
As the Industrial Internet of Things
(IIoT) movement advances, you have
to consider where you can automate
within your processes.
From an EPLAN standpoint, we
want to be part of the ecosystem of the
Industrial Internet of Things (IIoT),
states Ray Gaynor.
EPLAN takes data from conceptual
design and engineering through
the engineer processes and also
business processes efficiently, which is
an important set of capabilities as the
IIoT develops. We also collaborate to
adhere to global standards therefore
we can share information with other
suppliers and our customers.
With extensive experience in CAE
Sales and Operations, Ray has been
responsible for building successful
strategies and innovation throughout
the globe. He belongs to different
associations such as ISA, German
Chamber of Commerce and a
board member of WHMA. As an
Innovation leader in CAE
solutions, Ray educates the
industries on the importance
of automation through a true
Computer Aided Engineering
software such as the EPLAN
Solutions. Throughout the
different industries, one of the
main areas of focus is tying
data generated for the controls
design side of things intothe
overall electrical design.
The age of design automation is here, its
benefits are potentially enormous, and will
create a competitive edge for your business.
This bridge is essential to increased
productivity and automation within
their businesses so they can create
data one time and be able to
leverage that data throughout the
engineering process and also into the
manufacturing process. Simply, they
are trying to figure out ways to use
the same information created in
electrical design to design the cabinet
and to control the manufacturing
and assembly of the cabinet.
ADVERTISEMENT
Raymond
Gaynor
President,
Americas
Ray has assisted many companies in
reaching these goals through
the EPLAN Platform. The EPLAN
solutions includes software for
electrical design, fluid power, 3D
control cabinet and switchgear
design, plant and process automation
planning and layout and 2D/3D
wire harness design. The distinct
differentiator is that they all share
the same data allowing multiple users
in the same or different locations/
disciplines to work together in
real time.
EPLAN can even drive automated
manufacturing processes to CNC
machining of control cabinets and
Wire Processing machines.
Gaynor.r@eplanusa.com
+1 847-240-4655
www.eplanusa.com

I n order to seamlessly integrate
industrial data into IIoT, a new
communications platform is required.
This platform requires extensive
knowledge of the intricate realm
of OT and the state-of-the-art and
rapidly-changing domain of IT.
An Edge Solution for the Industrial
Internet of Things
Within OT, the platform must
understand the various network
topologies and data protocols that
will be encountered. It must be able
to automatically discover and
identify industrial Things and the
data they contain, as well as be able
to handle the storage of high-
frequency updates.
Within IT, the platform must be
able to transform the data it collects
and push it into the cloud via
IIoT standards.
As industry looks to build out the IIoT,
its biggest challenge will be seamlessly Internet-enabling
the Things that live at the edge of the network.
Emerging standards include
Asynchronous Messaging Queuing
Protocol (AMQP), Message
Queueing Telemetry Transport
(MQTT), Constrained Application
Protocol (COAP), and Data
Description Services (DDS).
These standards allow for the
retransmission of data in the event it
does not reach its destination.
With the lack of computer
networking infrastructure in OT, this
platform must be embeddable and run
within a standalone appliance or an
edge-based switch or router where IT
and OT converge.
Its flexibility will enable industrial
data to be sampled cyclically or
based on some event or condition
and be published to the cloud
independently of data collection.
Kepware Headquarters, Portland, Maine
Data filtering should be available
through basic analytics. Lastly, user
setup should be minimalized by
automating as much configuration
as possible.
As industry continues to define IIoT,
the concepts and realization of the
optimal Embedded IIoT Solution
will continue to evolve.
ADVERTISEMENT
Tony
Paine
CEO, Kepware
About Tony Paine
Tony Paine is CEO of Kepware
Technologies, a software
development company
headquartered in Portland, Maine
that provides a portfolio of
software solutions to help
businesses connect diverse
automation devices and software
applications and enable the
Internet of Things. Tonys main
focus is on the companys vision
and long-term strategy around
products and technology.
To read more on this topic and
download the Industrial Internet
of Things and Communications
at the Edge eBook, please visit
kepware.com/iot.
+1 888-KEPWARE iot@kepware.com
www.kepware.com/iot

K yland Corporation is playing a
leading role in advancing IEC
61850 and IEEE 1588 standards
for the Power Utility Industry
Automation and Smart Grids.
Power Distribution Automation is an
important part of todays Smart
Power Grids. Integration and
interoperability are essential for
grid operational efficiency and
system reliability. Smart Grid
technologies around the world are
helping to reduce power outages and
identify the root causes of blackouts
and brownouts; improving restoration
times and cutting operational costs.
Various standards have been
developed to help achieve accuracy
and compatibility. The 2 leading stan-
dards are IEC 61850 and IEEE 1588.
IEC 61850 is a standard for the
design of electrical substation
automation. The protocols can run
over TCP/IP networks or
substation LANs using high speed
switched Ethernet.
IEEE 1588 is the new standard for
Precision Time Protocol (PTP) used
to synchronize clocks throughout
the network. Accuracies have
been measured in the sub-
microsecond range.
In the IEC 61850 process bus,
digitized sampled values are
received in a synchronized structure
that makes sure algorithms in
protection relays and other devices
function properly.
This ensures that a timing accuracy of
1us (according to IEC 61850-5 & IEC
ADVERTISEMENT
61850-9-2LE) is achieved.
With PTP time synchronization
solutions IEEE 1588 ensures
migration paths meet industry
requirements. IEEE 1588 is the Kylands
SICOM3028GPT
standard for a Precision Clock and SICOM3306PT
Synchronization Protocol for
Networked Measurement and
Control Systems and is being adopted
by industrial network product
manufacturers around the world.
Kyland assisted in the creation of
three Global Industrial Computer
Network protocol standards:
IEC61158, IEC62439 and IEEE
C37.238 and hosted the 2015
International IEEE 1588 Symposium
on Precision Clock Synchronization
for Measurement, Control and
Communication (ISPCS.org).
Kyland Corporations Office in
Golden, Colorado
Kylands corporate tagline is
Industrialize Ethernet & Simplify
Communication and our vision is
to continually invest in R&D to
build game changing Industrial Our vision is to
Communication solutions for continually invest in
the future.
R&D to build game
Products like the SICOM3306PT changing Industrial
and the SICOM3028GPT
combine IEEE1588v2 and SyncE Communication
(ITU-T.G.8261/G.8262) bringing solutions for the future.
synchronization precision accuracy
to 100 nanoseconds which exceeds
the highest level of requirements for
clock synchronization solutions in
smart grid and power utilities.
For more information about
Kylands Power Utility focused
Kyland Corporation
products please visit us at Phone: 303.625.4006
www.kyland.com. www.kyland.com
 ADVERTISEMENT
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A s a world leader in drive
technology and a pioneer in
drive-based automation,
SEW-EURODRIVE has established
a reputation for quickly solving the
most difficult power transmission
and motion control challenges.
We introduced the gearmotor in
1931 and in the 84 years since
then, we have been bringing the
best in drive technology to our
customers worldwide.
U.S. Corporate Headquarters in
Lyman, South Carolina
Quickly solving problems so that our
customers can be more productive
and profitable continues to be our
priority. We offer the broadest
product line in the industry from
gearmotors and heavy industrial
gear units to electronic drives,
software and complete drive-based
automation systems.
We offer the broadest product line in the industry
from gearmotors and heavy industrial gear units
to electronic drives, software and
complete drive-based automation systems.
Our products are based on a unique
system of modular components that
can be assembled in literally millions
of different configurations so every
drive solution is custom built to our
customers exact specifications.
Our regional assembly centers stock
millions of dollars of our modular
inventory for quick delivery of drive
solutions and spare parts anywhere in
the U.S.
At SEW-EURODRIVE our
expertise doesnt stop with
the sale of our products.
We offer one of the most
accessible customer support
systems in the industry.
Our trained product
specialists are readily
available for on-site
start up assistance and
applications support.
In addition, our PT Pilot
drive selection quickly selects the
drive for your specific needs.
Our customer service personnel,
engineers, product specialists,
and service technicians are
available to answer questions
and troubleshoot problems.
SEW-EURODRIVE offers on-call
emergency technical support
around the clock.
ADVERTISEMENT
MOVIGEAR
Mechatronic
Drive System
The MOVIGEAR
Mechatronic Drive
System for horizontal
materials handling from
SEW-EURODRIVE sets new
standards in terms of efficiency
and functionality.
reduces total start-up cost
and annual operating costs
in your material handling
system by 20-30%!
MOVIGEAR not only combines the
gear unit, motor and drive electronics
within one highly reliable, efficient,
and hygienically designed unit, it also
reduces total start-up cost and annual
operating costs in your material
handling system by 20-30%!
Any opportunity to save energy is not
only an important contribution to
conserve the environment but also
pays off financially.
864-439-7537 www.seweurodrive.com

A llied Moulded Products, Inc.
is a leading manufacturer of
nonmetallic electrical boxes and
enclosures in todays residential,
commercial and industrial
markets. Leveraging more than
half-a-century of experience,
Allied Moulded has grown to
become the benchmark of quality
within the electrical industry.
Its full-service molding operation
includes expertise in compression
and injection molding, using ther-
moset and thermoplastic materials,
as well as a unique resin transfer
molding process. Utilizing a
modern, automated assembly
process, Allied Moulded provides
customer with a superior product
at a competitive price.
Allied Mouldeds unrelenting focus
on service, delivery, value,
innovation and technology in
everything it makes and does, has
made it what it is today.
Allied Mouldeds industrial
enclosures are found in control
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manufacturing plants, waste water
treatment, wind turbines, security,
SCADA, solar, marinas, data and
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more. The extensive line of
NEMA type 4X/IP66 fiberglass
reinforced polyester (FRP)
enclosures, made with its
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resin formulation, outperforms
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ing, gloss retention, discoloration
and change in texture. In addition
to fiberglass, Allied Moulded also
offers the POLYLINE series, a
line of polycarbonate, injection-
molded enclosures.
According to Glenn Saunders, Vice
President of Sales and Marketing,
Systems using automation and
controls are in every industry and
every environment. The use of
nonmetallic engineered materials
offers a multitude of competitive
advantages, such as reduced weight
and easier modification processes,
over traditional metal enclosures.
Allied Mouldeds enclosures are a
great alternative to steel, especially
in harsh environments.
Allied Mouldeds products are
marketed in the U.S. primarily
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Glenn Saunders
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through an extensive
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ce201601_execVc_ALLIEDMLDhalf.indd 1 12/11/2015 9:28:06 AM

F ounded in 1984, Dataforth is a recognized global
leader in the design and manufacture of signal
conditioning modules and industrial data acquisition
& control systems.
Our mission
has always been
to set the highest
standards of
product quality,
performance,
Corporate Headquarters, Tucson, Arizona and customer
service, says
Robert Smith, VP of Sales and Marketing. We know
that signal integrity is critical and so our products are
all designed to ensure the most reliable, cost-effective
isolation and protection for customers measurement
and control signals and connected equipment.
Unparalleled Data Acquisition & Control
MAQ20: Dataforths 3rd generation DAQ system
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Our signal conditioner families ensure outstanding accuracy, isolation, and
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Modules provide 1500Vrms transformer isolation, up to 240Vrms field-side
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SCM5B Analog Modules Ideal for temperature, pressure, flow
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H ARTING, first established
in 1945 and the inventor
of the rectangular connector,
is a global leader in connectivity
technologies.
HARTING develops, manufactures
and sells the worlds most
durable and reliable products and
solutions for use in: mechanical
and plant engineering,
transportation, broadcast and
entertainment, factory automation,
power generation and distribution
as well as industrial electronics
and telecommunication.
HARTINGs products include
electrical and electronic connectors,
device terminations, backplanes,
network components, as well as
cable harnesses for networks and
machinery, and for power and
data application in factories.
ce201601_execVc_halfHARTINGr1.indd 1
F or more than 30 years,
Maple Systems, Inc., has
supplied innovative control
solutions for the automation and
industrial controls marketplace,
and specializes in the design,
manufacture, and support of:
Touchscreen HMIs
HMI + PLC Combo Units
Remote HMIs
Panel PCs
Text-Based Operator
Interface Terminals
HMI Solutions for Every Machine
Maple Systems control
products are utilized worldwide
in industrial, OEM, automation,
and municipal applications.
Packaging, oil and gas, medical,
food and beverageNo matter
For more than 30 years our focus has been supplying innovative control solutions.
HARTING: The educational
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As an expert in the industry,
HARTING is committed to
educating the North American
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engineers need to make educated
buying decisions.
HARTING-U is HARTINGs
web-based content hub with tools
(white papers, FAQs, videos, and
more) that engineers need to find
the right technology for their
application. Visit HARTING-U.com
to start learning.
HARTINGs Knowledge Center
App gives users access to all of these
educational materials on their Apple
or Android devices. The HARTING
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customized experience by allowing
users to sort by market, product,
and content type so that they only
the industry, our solutions
streamline your process, offering
top quality and reliability. In
addition, Maple Systems provides
complimentary technical support,
and several Class I, Division 2
certified models.
Maple Systems Inc., Everett, Washington
PLC Integration
Maple Systems products integrate
with more than 100 brands of
programmable controllers from
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see information relevant to them.
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HARTINGs Configurator and
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Jon DeSouza
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HARTING also launched a
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12/17/2015 2:04:11 PM
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the biggest names in PLCs
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As a premier provider of industrial CEO Maple Systems
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control solutions at affordable you control?
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Maple Systems truly is your www.maplesystems.com
industrial control solution. Phone: 425.745.3229
NEW PRODUCTS and software
Camera series designed for
medical, food and beverage
applications
Teledyne Dalsas series of Genie
nano area cameras that deliver fast
frame rates for various vision applica-
tions such as intelligent traffic systems
(ITS), medical, food and beverage
inspection, and electronics and printed
circuit board (PCB) inspection. These
cameras have three resolution options,
including 640 x 480 (running up to 850
frames per second in VGA), 800 x 600,
and 1280 x 1024 pixels. The cameras
also feature trigger-to-image reliability
for easy system control and debug-
ging, housing for imaging in harsh
environments, two inputs, and two
opto-coupled outputs for integration
and deployment.
Teledyne Dalsa
www.teledynedalsa.com
Input #200 at www.controleng.com/information
Turbine flow meter series for oil
and gas, chemical applications
Badger Meters Blancett B1500 Series
turbine flow meter is designed for clean,
filtered liquid flow applica-
tions in precision industrial
processes such as batching,
blending, filling, or general
flow measurement in harsh
environments such as the
oil and gas and petrochemical
industries. B1500 Series turbine
flow meters feature mechanical
linearity to increase useable flow range
and help mitigate output variance caused by viscos-
ity fluctuations due to changes in fluid temperature. Flow rates and
totals are presented simultaneously via a crisp dot-matrix LCD
display and/or transmitted to a user interface via Modbus RTU, a 4
to 20 mA analog output, or totalizing pulse output.
Badger Meter
www.badgermeter.com
Input #203 at www.controleng.com/information
www.controleng.com
See more products daily at www.controleng.com/products.
Multi-touch HMI for SCADA,
MES applications
Kontrons FusionClient human-machine
interface (HMI) is an IIoT-ready industrial
computer platform family that combines an
edgeless, pure glass, multi-touch interface
with the Kontron COM Express computer-
on-module. It features multi-touch access
to real-time actionable data, which makes
FusionClient useful for real-time supervisory
control and data acquisition (SCADA) and
manufacturing execution systems (MES) monitoring and control applications. The
FusionClient is also prepared for gesture recognition, which enables a direct user
interaction without touching. FusionClient is also Wi-Fi-enabled for seamless con-
nectivity with plant machinery and other connected devices on the plant floor. The
FusionClient multi-touch displays are frameless and feature easy-clean front glass
that is anti-glare and scratch-proof as well as being IP65 front-side protected.
Kontron, www.kontron.com
Input #201 at www.controleng.com/information
Generation heat exchanger with proprietary technologies
Watlows Optimax is a generation heat exchanger that features proprietary
technologies and enhanced fluid dynamics (EFD) technology to provide
advanced flow throughout the system without compromising the fluids
integrity, heating elements, and/or vessel. It also features optimized film
temperature (OFT) technology in the heating elements, which is de-
signed to help fluid temperatures. These, coupled together,
provide an accelerated heat transfer rate, allowing
the vessel to perform consistently at shorter
lengths, or smaller shell diameters.
Watlow
www.watlow.com
Input #202 at www.controleng.com/information
Electro-hydraulic valve
actuators for oil and gas
operations
Rotorks Skilmatic electro-hy-
draulic valve actuators combine to
facilitate remote supervision with
asset management that encompass-
es accurate control, monitoring
and alarm signaling, operational
data logging, and diagnostics. They
are designed for emergency shut-
down (ESD) duties for oil and gas
applications. They can be used for
automated and unattended valve
chambers at pump stations and are
designed to isolate sections of a pipeline in the event
of a potential emergency. Additional options include
a second ESD circuit and a manual reset. The actuator
has a double-sealed electric enclosure that is water-
tight and dustproof and rated up to IP68.
Rotork, www.rotork.com
Input #204 at www.controleng.com/information
CONTROL ENGINEERING JANUARY 2016 | 61
NEW PRODUCTS and software
See more products daily at www.controleng.com/products.

EtherCAT I/O controller for

Software for CAD assemblies
and mechanical designs
Maplesofts MapleSim CAD Toolbox
is designed to allow engineers to un-
derstand and improve their mechanical
designs by bringing their computer-
aided design (CAD) assemblies into
the MapleSim modeling and simulation
platform. The MapleSim CAD Tool-
box imports CAD models directly into
MapleSim, recreating the model compo-
nents and preserving their kinetic and
kinematic properties as well as the spatial
relationships between components. It
also offers feature detection, which allows
users to add new coordinates at points
of interest. It can also share coordinate
frames between separate bodies, which
are designed to help ensure the bodies
will be properly aligned when joined.
Maplesoft, www.maplesoft.com
Input #205 at www.controleng.com/information
automation systems
Galil Motion Controls RIO-574x0 EtherCAT slave
I/O controller is packed with digital and analog I/O
to be used remotely in an EtherCAT automation
system. The RIO-574x0 can be used with any generic
EtherCAT master and is also designed to integrate into
an EtherCAT system with Galils DMC-500x0 EtherCAT
master. All RIO-574x0 controllers have 16 opto-isolated
digital inputs and 16 high-power opto-isolated digital outputs.
The RIO-57420 also includes eight analog inputs (4 to 20 mA option
available) and eight analog outputs, both configurable in the ranges of 0
to 5 V, 0 to 10 V, and 5 V or 10 V. Input/output (I/O) points are accessible via
screw terminals, and LED indicators are provided for all digital I/O points.
Galil Motion Control, www.galilmc.com
Input #206 at www.controleng.com/information
Electromechanical cylinder for applications
with frequent cleaning cycles
Bosch Rexroths electromechanical cylinder with hygienic design
and IP65 protection is suitable for applications with frequent cleaning
cycles in the food industry. The EMC100-XC-2 increases
the power density for feeding forces of up to 56 kN for
applications in forming technology. The screws on the
end face can be optionally sealed. For use in applications
with particularly aggressive cleaning agents, the version
in IP65+R has seals and scrapers made from chemically
stable materials. It also features a pressure compensa-
tion port designed to prevent overpressure or nega-
tive pressure in the cylinder.
Bosch Rexroth, www.boschrexroth-us.com
Input #207 at www.controleng.com/information

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KYLAND. . . . . . . . . . . . . . . . . . . . . .9 . . . . . . . . . . 6. . . . . . . .www.kyland.com
Content For Engineers. Thats what CFE
MICROMO . . . . . . . . . . . . . . . . . . . .15 . . . . . . . . 10 . . . . . . .www.micromo.com Media stands for, and what CFE Media is all
about engineers sharing with their peers.
Moore Industries - Intl. Inc . . . . . . .4 . . . . . . . . . . 4. . . . . . . .www.miinet.com We welcome content submissions for all
interested parties in engineering. We will use
Moxa Technologies . . . . . . . . . . . . .3 . . . . . . . . . . 3. . . . . . . .www.moxa.com those materials online, on our website, in
print and in newsletters to keep engineers
Omega Engineering Inc . . . . . . . . .27 . . . . . . . . 12 . . . . . . .www.omega.com informed about the products, solutions and
industry trends.
Phoenix Contact . . . . . . . . . . . . . . .44 . . . . . . . . 23 . . . . . . .www.phoenixcontact.com/GoMesse www.controleng.com/contribute explains
how to submit press releases, products,
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case studies, white papers, and other media.
SEW-EURODRIVE, Inc. . . . . . . . . . .C4 . . . . . . . . 27 . . . . . . .www.seweurodrive.com
* Content should focus on helping engi-
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mercial in nature or that are critical of other
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(Technology discussions and comparative
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and if contributor corroborates information
with sources cited.)
Inside Process * If the content meets criteria noted in
guidelines, expect to see it first on our Web-
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from content already available on our Web-
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zines will appear as space permits, and we
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article is available online.
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the print magazines are at least two months in
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to discuss all feature articles with the appropri-
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www.controleng.com CONTROL ENGINEERING JANUARY 2016 | 63

 BACK TO BASICS wireless

Open standard wireless systems

Open standard wireless systems include Bluetooth, Z-Wave, ZigBee, Worldwide interoper-
ability for microwave access (WiMAX), ISA 100.11, and wireless highway addressable remote
transducer (WiHART). Each technology has specific advantages for particular industries.

T
The present situation of open wire-
less systems and standards in use is reminiscent of
an earlier time when wired networks first became
viable. Each system had good and bad points. The
good points were incorporated into modern sys-
tems. This situation is unfolding in wireless systems.
for monitoring of smart grids. WiMAX can provide
Internet service wirelessly across large geograph-
ic areas from fixed WiMAX stations. WiMAX
requires gateway devices at the subscriber location,
which will interface with or contain an integrated
Wi-Fi access point or router. The maximum range
for WiMAX is 30 miles, with optimum speeds of

Types of open wireless standards
Maximum range Wireless highway addressable remote transduc-
er (WiHART) is the wireless implementation of the
for WiMAX is wireline HART protocol. WiHART adheres to the
IEEE 802.15.4 open standard, but only at layers 1
30 miles, with and 2 of the open systems interconnection (OSI)
model. The HART protocol allows for the monitor-
optimum speeds ing and configuration of remote instrumentation,
eliminating the need to go to the device to perform
of 10 MBPS being these functions. The system works with HART-
capable instrumentation. Some capital expenditure
attained at a
is needed, but utility and economy are astonishing.
range of one to Z-Wave wireless technology operates in the 900
MHz spectrum, is used for home automation, and
10 MBPS being attained at a range of one to six
miles. WiMAX also uses licensed and unlicensed
spectrum as opposed to Wi-Fi and others, which
operate in unlicensed spectrums. WiMAX is used
globally, but use of long-term evolution (LTE) has
caused several networks to be shut down.
Wireless instrumentation standard
ISA 100.11a is the last iteration of a wireless
instrumentation communication standard being
promoted by the International Society for Auto-
mation (ISA). ISA 100.11a is similar to WiHART.
ISA 100.11a is based on IEEE 802.15.4. Although
WiHART specifies and enforces operation-

six miles.
MORE
ADVICE
KEY CONCEPTS
A number of open wireless systems
are designed for automation and
manufacturing industries.
Some of the open wireless standards
include WiHART, WiMAX, ZigBee, and
Z-Wave.
ISA 100.11a is designed for imple-
menting proprietary networks.
GO ONLINE
Learn more about about ISA stan-
dards and regulations and see more on
open wireless standards:
www.controleng.com/blogs
CONSIDER THIS
What other open wireless systems
could be useful, depending on the
setting?
has become the de facto home automation wireless
standard with widespread support and interop-
erability by and between vendors. It offers back-
wards compatibility with prior versions. Z-Wave
operates in the 900 MHz spectrum and creates a
mesh network. Each node acts as a repeater and
has a line-of-sight (LOS) range approaching 100 ft.
For most households, this range is adequate. Sig-
nals can be repeated up to four times, for greater
reach. Z-Wave communicates at low data rates and
a Z-Wave gateway is required to control the system.
ZigBee (based on IEEE 802.15.4), can provide
a wireless interface with many devices from home
awareness and automation (A/A) to home enter-
tainment device controls. It is geared towards low-
rate communication devices, topping out at 250
KBPS. It has a range of about 35 ft, comparable to
Bluetooth, which allows seven devices to pair; Zig-
Bee allows 65,000. ZigBee, a mesh network, oper-
ates in 900 MHz and 2.4 GHz spectrums.
Worldwide interoperability for microwave
access (WiMAX) is a family of communication
standards based around the IEEE 802.16 standard,
also known as metropolitan area networks (MAN).
WiMAX was originally conceived as an alternative
to wired DSL and cable service for last mile or
al parameters (for interoperability), ISA 100.11a
allows users to configure parameters to unique net-
work values and constituent devices. ISA 100.11a
does not specify encryption or an application layer
interface, and routing between devices is optional.
It is apparent ISA 100.11a was intended for
implementing proprietary networks, so each ven-
dor can tweak operational parameters so one ven-
dor can communicate. Interoperability was not
considered unless it is within a single-vendor
implementation. Vendor cooperation could enable
interoperability. Several vendors offer ISA 100.11a
functionality, but all communicating devices must
conform to the same configuration; in this sense,
the standard is not open. It can be argued that this
standard is customizable since it can be made to
operate in a mixed radio frequency (RF) environ-
ment and be made incompatible with every other
device operating in the same spectrum. ce
Daniel E. Capano, owner and president, Diversi-
fied Technical Services Inc. of Stamford, Conn., is a
certified wireless network administrator (CWNA);
dcapano@sbcglobal.net. Edited by Chris Vavra, pro-
duction editor, CFE Media, Control Engineering,
cvavra@cfemedia.com.

64 | JANUARY 2016 CONTROL ENGINEERING www.controleng.com

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wasted on energy? Independent research proves that the
MOVIGEAR from SEW-EURODRIVE can reduce your
startup and operating costs by 20-30%. In fact, some
installations actually yield 50% or more!

MOVIGEAR MOVIGEAR combines the gearing, permanent magnet

motor (IE4), and electronics into a single hygienic unit.
Or, if you prefer using your existing gear units, the DRC
Electronic motor (IE4) is the solution. MOVIGEAR or
DRCeither way, you save big bucks!

DRC Electronic Motor

movigear.com / 864-439-7537 input #27 at www.controleng.com/information