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What’s Next with the IEC/ISO 17305 Safety Standard?

Auto Company Makes the Most of Integrated Architecture

Automation Fair 2016 in Review

Root Cause of Safety Downtime

Use data and greater connectivity to help boost safety, compliance and productivity.

FEBRUARY 2017PRSRT STDUS POSTAGE

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THE JOURNAL | FEBRUARY 2017 WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL4

©The Journal From Rockwell Automation and Our PartnerNetworkTM, 2017, Volume 24 Number 1, is published six times a year by PUTMAN MEDIA, INC., 1501 E. Woodfield Rd., Suite 400N, Schaumburg, IL 60173 (Phone 630/467-1300). Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©The Journal From Rockwell Automation and Our PartnerNetwork 2017. All trademarks, company names and product names referred to throughout this publication are used for identification purposes only and are the properties of their respective companies. All rights reserved. The contents of this publication may not be reproduced in whole or part without consent of the copyright owner, including digital reproduction. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the industrial automation industry at no charge. To subscribe or unsubscribe, email Theresa Houck at [email protected]. Putman Media Inc., which also publishes Chemical Processing, Control, Control Design, Smart Industry, Pharmaceutical Manufacturing, Plant Services, and Food Processing, assumes no responsibility for validity of claims in items reported. Putman Media, Inc. is not affiliated with Rockwell Automation, Inc. “The Journal From Rockwell Automation and Our PartnerNetwork” is a trademark of Rockwell Automation, Inc. and its use in the title and masthead of this publication is by license granted by Rockwell Automation, Inc. to Putman Media Inc. Some photographs and other illustrations printed in this publication may be used with safety equipment removed or altered for illustrative purposes. However, in actual operation, it is recommended that all correct safety procedures and equipment always be utilized.

With the IEC/ISO 17305 Safety 16Standard Delay, What’s Next?While the future merged standard for global machine safety still remains unclear, expect changes to ISO 13849 and IEC 62061.

Automotive Company Makes the 19Most of Integrated ArchitectureLearn how an OEM provides efficient, flexible equipment for users’ tire-rubber mixing processes.

Attendees Connect at 2016 22Automation Fair EventEducational sessions and exhibitors share industrial automation solutions, trends in the IIoT, and advantages of The Connected Enterprise.

Tips for Modernizing Automation 32TechnologiesLearn what to consider when updating operations technology to help maximize efficiency, boost agility, increase ROA and keep up with customer demands.

Remember the Basics for Pneumatic 35System SafetyThree primary methods commonly are applied to valve terminals to meet safety requirements and operational demands of various applications.

How to Pick the Proper Flow Meter 40This thorough guide covers common technologies used in flow instruments and key factors to consider when selecting a meter for optimal process operation.

February 2017

CONTENTS

FFeebbrruuaarryy 22001177

CONTENTS

Root Cause of Safety Downtime

8Use data and greater connectivity to help boost safety, compliance and productivity.

FEATURES

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February 2017JOURNL-BR037A-EN-P

19

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DEPARTMENTS

Editor’s Viewpoint 7OEM Partner Profile 45Encompass Showcase 47Product Focus 48Ad Index 50

WEB-EXCLUSIVESVisit www.rockwellautomation.com/thejournal to access these Web-only bonus articles!

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>> Your safety system is talking to you. Are you listening?

� e data generated by your safety system is narrating a valu-able play-by-play of what’s happening with the machine. � e key player is employee behavior — their use (or perhaps misuse) of safety systems can reveal if a machine is being operated signifi cantly diff erent than intended.

People in the areas of safety, production engineering and IT use safety data, but they’re usually not sharing the results of their analyses. As this issue’s cover story explains, however, all these folks can use data about safety-related downtime to help improve safety, compliance and productivity.

Here’s just one example. Say an operator should access a door twice per shift to feed the machine. If the data shows the door isn’t being opened, that could indicate either the door’s safety interlock has been overridden, placing workers in danger, or the operators have fi gured out an alternative way to feed the machine, for better or worse.

If the door is being accessed many more times than designed, this could indicate that there are feed problems operators have to address and that the safety interlock will fail earlier than designed because of overuse and should be replaced earlier than expected to maintain compliance.

Access to this kind of safety system data can be a powerful tool in fi nding the root cause of problems and help you protect workers and improve uptime. Learn more in our cover story. Until next time …

YOUR SAFETY SYSTEM IS TELLING A STORY

FEBRUARY 2017, VOLUME 24, NO. 1

In Memory of Julie Cappelletti-LangeVice President 1984-2012

Putman Media, Inc.1501 E. Woodfi eld Rd., Suite 400NSchaumburg, Ill. 60173, 630-467-1300

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VIEWPOINT

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>> Production information may get all the glory, but safety information also has a

valuable story to tell. “Information is one thing, but safety information is quite another,” George Schuster says. He should know. He’s charged with business development for the Global Safety Team of Rockwell Automation and has seen many plants and factories begin to use safety data in new and innovative ways.

“� e interesting thing for me as a safety guy is the use of safety KPIs (key performance indicators) and analysis to highlight employee behavior, use and sometimes misuse of safety systems,” Schuster ex-plains. “Safety data is also used by EHS (environmen-tal, health & safety), production engineering and IT people. � ese folks don’t normally hang out together.”

By working together, however, these operations teams can use new tools to look at safety information in valu-able new ways. � ey can, for example, combine overall performance information with safety information to determine the root cause of unplanned downtime.

“A typical operations team may be looking at a machine to check part counts, uptime and down-time,” says Dave Krieger, information software regional manager, Rockwell Automation. “A lot of times, they’re looking for root cause. It could be the operator stopped it, a mechanical fault or someone

broke a light curtain. Now you can take the overall performance information and add safety information, which gives the team another tool to determine the root cause of unplanned downtime.”

Real-Time Safety MetricsRockwell Automation has some new tools to help understand the causes of downtime related to safety, and operations teams can start to investigate incidents in context. For example, if an emergency stop button is pressed on a machine, a pop-up displays on a Facto-ryTalk® View SE application asking the operator to select the cause from a list. � is provides consistent, detailed reasons to assist fi nding the root causes of downtime.

“So using FactoryTalk Metrics, I integrated standard OEE (overall equipment eff ectiveness) data collection as part of the measurement of the machine performance, but then I also created a new set of categories associated with the safety function of the machine,” Krieger explains.

“� is gives an operations or EHS person more infor-mation to investigate, helps with auditing things such as stop times, and helps automate the reporting process. � e valuable safety information that was just displayed at the machine is now making it to a connected database for analysis.”

New access to data about safety-related downtime and higher levels of connectivity bring a turning point for improving safety, compliance and productivity.

Root Cause of Safety Down time

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Root Cause of Safety Down timeof Safety Down time



Data that can be collected from an emergency stop’s activation include the time stamp, downtime duration, and the line and shift associated with each activation. Stoppage reason codes

also can be incorporated to capture why a machine was stopped, such as for jams, misfeeds or cleaning.

And it’s not just emergency stops. Data can be collected for nearly any

safety function, including safety mats, guard doors or gates, light curtains, and lockout/tagout (LOTO) proce-dures. Data from multiple functions also can be tied together to better understand the relationships between them or to examine sequence timing.

Much of the safety data already is available in the machine, so collecting it and putting it into an analytical tool package, using � e Connected Enter-prise, won’t slow down the controller.

“With FactoryTalk View SE, we can see safety status, and we contextu-alize the safety information using the reports from FactoryTalk Metrics,” Schuster notes. “It’s something that when we sit down with an OEM, they realize the value, and they can pass that on to their customer.”

Performance vs. IntentOEM Bevcorp supplies fi lling and blending equipment and services for the beverage industry and won the 2014 Manufacturing Safety Excel-lence Award. � ey featured a typical use case for safety data at the 2016 Automation Fair® event Rockwell Automation Safety Solutions exhibit.

“When you do a risk assess-ment on a machine concept, you get a design intent for access to the machine,” Schuster explains about Bevcorp. “For example, what does the guy do when he opens the guard door? How often does he do it? And how long does that task take? � ese are all analytics learned by analyzing the tasks and hazards when perform-ing a risk assessment.”

“� e data forms the design intent and the baseline analytics for the machine,” he continues. “If the gate is accessed fi ve times per shift, � e Connected Enterprise will collect the data, analyze it in a historical way and compare that data to the design intent.

“If frequency of access is 20 times per shift, that’s a red fl ag. Is the op-

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erator using the guard door for some other purpose than the design intent, possibly increasing operator risk or causing a compliance issue? On the other hand, zero access frequency

may indicate the guard is bypassed. � e safety information can be compared across diff erent operators, shifts and lines, and even diff erent plants,” Schuster says.

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>> Rockwell Automation Partners Support Safety

Many members in the Rockwell Automation PartnerNetwork™ (www.rockwellautomation.com/partners) provide technologies that support network safety automation and complement Rockwell Automation solutions. Visit their websites to learn more about how they can help you.

Brady Corp., Encompass™ Product Partner: Lockout/Tagout Devices www.rockwellautomation.com/go/p-brady

Festo Corp., Encompass Product Partner: Pneumatic Safety Valves www.rockwellautomation.com/go/p-festo

Flowserve Corp., Encompass Product Partner: Digital Valve Positioners www.rockwellautomation.com/go/p-flowserve

Grace Engineered Products, Inc., Encompass Product Partner: Safety - Permanent Electrical Safety Deviceswww.rockwellautomation.com/go/p-grace

Littelfuse Inc., Encompass Product Partner: Arc-Flash Protection www.rockwellautomation.com/go/p-littlefuse

MB Kit Systems Inc., Encompass Product Partner: Safety Hard Guard-ing and Special Safety Enclosureswww.rockwellautomation.com/global/go/p-mbkit

Metso Flow Control Inc., Encompass Product Partner: Intelligent Safety Solenoid and Partial Stroke Testing Systemwww.rockwellautomation.com/go/p-metso

Panduit Corp., Strategic Alliance Partner: Lockout/Tagout Devices, Arc-Flash Hazard Labels www.rockwellautomation.com/go/p-panduit

Ross Controls, Encompass Product Partner: Machine Safety Pneumatic and Isolation Valves www.rockwellautomation.com/go/p-rosscontrols

SMC Corp., Encompass Product Partner: Safety – Machine, Pneumatic Safety Valves www.rockwellautomation.com/go/p-smc


For more information, go to: www.rockwellautomation.com/go/tjsi

SECONDRY IMAGE AREA

PartnerNetwork is a registered trademark of Rockwell Automation, Inc. Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. AD2013-23-US PUBLICATION CODE FOR

AD CREATOR FILES ONLY

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Collecting and contextualizing safety information is only the beginning. The real value comes in putting it to use.

Safety information in � e Connected Enterprise off ers insight into such leading indicators of safety and compliance.

Information-Driven ImprovementsCollecting and contextualizing safety information is only the beginning. � e real value comes in putting it to use.

For example, safety-system diagnostics can be used to simplify troubleshooting and improve resolution times for safety-related failures. Alternatively, the diagnostics can be used in a more proactive manner to help prevent failures in the fi rst place. Using safety information for predictive analytics, for instance, allows operators to identify leading indicators and address machine issues before they become downtime events.

Safety and operations professionals also can use safety-re-lated downtime information to develop mitigation plans that

help improve productivity. Such plans could include provid-ing retraining for operators on specifi c lines or shifts where downtime issues are most frequent. Or they could involve updating procedures to address specifi c downtime issues that are widespread across a plant or operation.

Compliance is another area of opportunity. Today, safety data primarily is collected through manual audits for compliance and reporting purposes. However, this can be time-consuming and be subject to human error.

In a Connected Enterprise, organizations can integrate these auditing functions into the HMI and controller to automate and speed up the auditing process. � is also can help free up personnel to focus on other priorities and reduce the likelihood of errors.

Enhancing Safety with ConnectivityA Connected Enterprise can help companies reimagine their approach to safety. � e ability to connect people, equipment and worksites can create inherently safer operations.

A key example of this is in the use of manned topside platforms in off -shore oil and gas production. � ese platforms can present safety risks, from explosions to ship collisions. Ethernet-connected subsea platforms provide a potentially safer alternative to manned platforms, with gas directly pumped from the seabed to onshore production facilities.

Even small changes can help enhance safety. Incorpo-rating wireless and mobile technology, for example, can deliver information in a more convenient and ergonomic way to reduce strains on older workers. Likewise, wearable sensors can locate workers in underground mines or other hard-to-reach places during an emergency. In addition, video, voice and display technologies can be used to help track and communicate with these workers should an incident occur.

Watershed Moment for SafetyUnprecedented access to safety information and new levels of connectivity represent a turning point for safety compliance and productivity. � ese capabilities create new opportunities to understand risks, enhance safety and improve productivity. And yet they still only scratch the surface of what’s possible in a Connected Enterprise.

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>> The movement toward a single global machine-safety standard has been a long time coming,

and now it’s going to be a little longer.� e merger of safety standards ISO 13849 and IEC

62061 into one standard, IEC/ISO 17305, was sched-uled to take eff ect this year. However, the project was cancelled, at least for now, based on decisions made at the October 2015 plenary meeting of ISO technical com-mittee ISO/TC199.

With signifi cant discrepancies existing between the ISO and IEC standards, the committee simply couldn’t reconcile those diff erences within the time constraints of its deadline. As a result, IEC/ISO 17305 is stopped, and its long-term future won’t be defi nitively known until after the next IEC/TC44 and ISO/TC199 plenary meeting in March 2017.

Despite the proposed merger’s setback, machine design-ers still can expect to see changes to global machine-safety standards in the coming years. After all, although IEC/ISO 17305 currently is cancelled, its longer-term future

still is under consideration. In the meantime, updates to the ISO 13849 and IEC 62061 standards are in the works.

The Evolution of Machine-Safety StandardsAny eventual re-implementation of the IEC/ISO 17305 merg-er process would represent another step forward in the evolu-tion of safety standards. But even without the merger process, the evolution will continue in the form of further updates and continued convergence of ISO 13849 and IEC 62061.

� ese two standards have many similarities, but they also have distinctions that set them apart for use with dif-ferent types of machinery.

ISO 13849 primarily is used for conventional machines and equipment, including those used in discrete production in which only a simple, self-contained design and validation methodology are required. On the other hand, IEC 62061 typically is used for more complicated machines and equip-ment that require more complex safety functions and more fl exibility, such as those used in process applications.

WITH THE IEC/ISO 17305 SAFETY STANDARD DELAY, WHAT’S NEXT?

While the future merged standard for global machine safety still remains unclear, expect changes to ISO 13849 and IEC 62061.

By Derek Jones, safety business development manager, Rockwell Automation

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� e transition to these two standards was a signifi cant leap for many machine designers. Switching from simple machine-safety categories to performance level (PL) and safety integrity level (SIL) models brought on greater complexity. It also resulted in confusion about when SIL-qualifi ed components can be used in PL-qualifi ed systems, or vice versa, and created extra training demands to help verify engineers understand both standards.

At the same time, the added value that these two standards have brought to the safety-compliance process is undeniable. � e standards’ support of new, programma-ble-safety technologies helps end users meet safety require-ments while enhancing productivity. � e two standards also provide a simplifi ed means for machine builders and end users to achieve safety compliance in multiple markets around the world.

When Two Standards MeetOne company that’s been able to capitalize on the advantages of IEC 62061 and ISO 13849 is Wisconsin-based Paper Con-verting Machine Company (PCMC), a Rockwell Automa-tion OEM Partner (www.rockwellautomation.com/global/go/pcmc). � e company specializes in tissue converting, packaging, fl exographic printing and nonwoven technology. It is using the two standards to make safety an integral part of its design process and legacy equipment upgrades.

“It’s really a change in philosophy,” says Jill � iede, strategic accounts manager for PCMC. “Now, we can design an inte-grated safety system that reduces machine hazards and associ-ated risks — and improves overall effi ciency and productivity.”

PCMC now can use the standards to implement con-temporary safety technologies.

For example, it can use zone control to divide a com-plex converting line into safety zones that correspond to specifi c risks or hazards. � e system can be confi gured to remove power safely from one zone so a maintenance technician can service it, while keeping the rest of the line up and running.

Preparing for ChangesIf IEC/ISO 17305 ever comes to pass, it will be years from now, and it likely will encounter some degree of resistance

just as any standards change does. However, machine de-signers should fi nd their migration to and understanding of the current IEC 62061 and ISO 13849 standards will make their migration to whatever evolves more manageable.

� ose who are concerned with understanding the rela-tionship between the two standards, and the potential areas of convergence between them, can start by studying ISO TR 23849 or IEC/TR 62061-1. � ese technical reports pro-vide helpful interpretations of ISO 13849 and IEC 62061 and off er guidance on each standard’s specifi c applications.

Meanwhile, as mentioned previously, work already is underway on the next editions of the IEC 62061 and ISO 13849 standards. � e two standards bodies will be able to use the work that already was completed on IEC/ISO 17305 to help keep the revised editions on a converging path. � e revised standards likely will be released in the next few years.

As far as potential changes to expect for ISO 13849, machine designers may get some relief from the quantifi -cation and calculation burdens required for more simple and deterministic systems. IEC 62061 may include addi-tions and improvements that address new factors, such as low-demand safety applications, to cover a wider range of equipment and machinery.

Still, even as these changes are made, the two stan-dards’ basic requirements will stay the same. � at’s why it’s important that machine designers commit to understand-ing and making the most of ISO 13849 and IEC 62061. � is is especially true for safety professionals who are responsible for updating and maintaining their organiza-tions’ corporate safety standards.

� ose who commit to understanding the existing stan-dards will be better prepared to develop higher-performing and internationally competitive machinery, while also containing the costs of multinational safety compliance. � ey’ll also be better positioned in the future to migrate to the revised standards — and eventually to a single converged standard, if it happens.

Rockwell Automation Safety Solutionswww.rockwellautomation.com/global/go/safety-management

Those who are concerned with understanding the relationship between the two standards can start by studying ISO TR 23849 or IEC/TR 62061-1.

As far as potential changes to expect for ISO 13849,

TJ1702_16_17_F2_safetystandard.indd 17 2/6/17 2:02 PM

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>> Increased tire performance requirements demand integrated automation solutions. In

particular, rubber-mixing is a complex combination of several individual processes that can be optimized with modern control technology. At the 2016 Automation Fair® event Automotive Industry Forum, Hans-Martin Monyer, head of automation and systems at HF Mixing Group, described requirements for processes and performance in a rubber-mixing room. With an assist from the Rockwell Automation Integrated Architecture® system, his company provides equipment for tire-rubber processes.

“Every machine builder, every manufacturer, feels pressure to increase performance,” said Monyer. He also re-viewed for the audience technologies available to manufac-ture, build and develop new automation systems for mixing; explained how HF uses integrated solutions for its mixing rooms; and talked about his company’s modern approach.

Automation as a ProductHF is part of the international Possehl Group, which consists of about 150 companies with 12,000 employees. HF focuses on providing equipment and complete solu-tions for rubber-mixing plants. It designs complete mixing systems, including related upstream and downstream equipment, and provides the necessary interfaces and manufactures and commissions the equipment. It takes full turnkey responsibility for both greenfi eld and brown-fi eld applications. HF’s automation group consists of more than 100 employees located worldwide.

“� e automation itself is a product,” said Monyer. “HF has standardized the automation product using a develop-ment group consisting of IT engineers, PLC engineers and drive engineers. � e systems are engineered, commissioned and supported, and HF also provides customer workshops.

“We understand the challenges, such as costing, quality and effi ciency, along with the new raw materials and sophis-ticated processes that all must come together in our new products,” he explained. “� e questions we always raise are ‘What is the role of automation in all of this?’ and ‘How can automation support our customers with these challenges?’”

Mixing room processing begins by weighing ingredients, proceeds to chemical preparation and then moves to mixing. After the mixer drops the batch, the materials are moved into a continuous process. “� e challenge is to bring all these elements together to make one complete process,” Moyner said. “� ere are also many individual machines in the mixing room that must be brought into an overall solution.

“� e most challenging part is effi ciently dealing with the resources,” Monyer added. “Raw materials are a big part of the cost of a tire, as is energy. Human resources must also be managed.”

Assembling the TechnologyTechnology is available to provide intelligent and effi cient solutions for automating the mixing room. “Rockwell Au-tomation was very helpful and introduced us to its High Performance Architecture, which combines and integrates information and control technology,” commented Monyer.

AUTOMOTIVE COMPANY MAKES THE MOST OF INTEGRATED ARCHITECTURE

Learn how an OEM provides effi cient, fl exible equipment for users’ tire-rubber mixing processes.

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To automate the mixing room, equipment communi-cation needed to be integrated. EtherNet/IP™ tied it all together, while integrated software — in this case, Studio 5000 Logix Designer™ software (www.rockwellautomation.com/go/studio5000) — was used to confi gure, program and maintain the discrete, batch, process, motion, safety and drive functionalities. “It was also used to develop user-friendly human-machine interfaces,” he said.

IT and OT IntegrationHF worked with Rockwell Automation to integrate the IT and operations technology (OT) aspects of a complete mixing system. HF applications control the complete workfl ow, from receiving to printing a barcode label for the fi nal package. To control and plan for required resources effi ciently, HF provides a set of

applications that includes production and inventory planning systems as well as overall equipment eff ective-ness (OEE) dashboards. HF also is working to imple-ment the new Allen-Bradley® PowerFlex® 755 drive from Rockwell Automation (www.rockwellautomation.com/go/tjpf755) in new applications.

“� e system that controls the process allows us to im-prove performance and quality while reducing scrap and rework,” noted Monyer. “It allows us to integrate IT and OT and to provide our customers with the information they need to make faster decisions. It has been a profi table collaboration with Rockwell Automation and HF and it is bringing added value to the tire industry.”

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>> More than 10,000 representatives from manu-facturers, OEMs, industry analyst groups,

media and Rockwell Automation member companies in its PartnerNetwork™ (www.rockwellautomation.com/partners) from around the world descended into the Geor-gia World Congress Center in Atlanta Nov. 9-10 to see the leading technology and solutions in industrial automation. The 25th Automation Fair® event offered attendees the opportunity to share information about the latest control system network infrastructure using IP-based networks like EtherNet/IP™, safety, power and information tech-nologies that support The Connected Enterprise (www.rockwellautomation.com/go/connected).

Attendees also visited more than 100 exhibitors displaying the latest automation products and solutions from Rockwell Automation and its PartnerNetwork™ members, including Encompass™ Product Partners, Solution Partners (system integrators), OEM Partners and Strategic Alliance Partners.

Visitors also had free access to automated control and information solutions, and advanced automation tech-

nologies from the industry’s best suppliers. Rockwell Automation designed the event to help improve custom-ers’ innovation, productivity and collaboration through educational off erings that included nine industry forums, 93 technical sessions and 19 hands-on labs about the latest control, power and information technologies.

In addition, prior to the Automation Fair® event, the popular Process Solutions User Group (PSUG, http://psug.rockwellautomation.com) took place Nov. 7-8.

Connectivity Brings ProductivityAt the 2016 Automation Fair® event Automation Perspec-tives global media forum, Rockwell Automation chairman and CEO Blake Moret shared with journalists and indus-try analysts the company’s own journey to � e Connected Enterprise, what’s driving more factories to become more connected, and why it’s important to converge IT and operations technology (OT).

“� e combination of technology innovation and applica-tion expertise is transforming industrial processes, making

Educational sessions and exhibitors share industrial automation solutions, trends in the IIoT, and advantages of The Connected Enterprise.

By Amanda Joshi, Managing Editor

ATTENDEES CONNECT AT2016 AUTOMAT ION FAIR EVENT

TJ1702_22_29_F4_autofair.indd 22 2/6/17 2:23 PM


it possible for companies to become more integrated and competitive,” said Moret. “Our vision — called � e Connected Enterprise — brings to-gether power, control and information solutions to respond to the increased demand for global productivity.”

Information management and ana-lytics are off ering another level of pro-ductivity and are increasingly taking place in instruments and controllers, as well as on servers and in the cloud.

“� ere’s been a lot of general conver-sation about the Industrial Internet of � ings (IIoT), and now we’re starting to make it real in applications such as serialization, track and trace, compli-ance and scheduling,” Moret said.

By understanding work practices and potential savings, Rockwell Au-tomation plants have reduced work in process (WIP), error-proofed

procedures and rework. “Results like ‘reduced time to market’ are tangible and drive sales for us,” explained Moret. “Each plant starts from a unique point, with its own opportunities to add value.”

� e company is now on Phase 2 of their Connected Enterprise journey, adding data streams from its supply chains, and using the cloud to complement onsite systems. “In the end, it doesn’t reduce the number of people, but it does change their work,” Moret added. And it provides insight Rockwell Automa-tion can apply to customers. “Out in the market, there’s not a lot of new capital investment going on — most projects are brownfi eld upgrades and expansions. We must catch customers at that point in their history, not as greenfi eld projects.”

Central to achieving � e Con-nected Enterprise is the need to converge IT and OT. Historically, these functions worked independently. Today, the convergence of IT and OT is critical to the success of an indus-trial enterprise, enabling businesses to gather, analyze and transform data into actionable information for deriv-ing tangible business outcomes, and making production safer, predictable and more sustainable.

ATTENDEES CONNECT AT2016 AUTOMAT ION FAIR EVENT

November 15-16George R. Brown Convention CenterHouston, Texaswww.automationfair.com

>> Plan Now for 2017 Automation Fair Event



Moret recognizes the importance of fi nding technol-ogy-savvy people integral to converging the IT and OT to build � e Connected Enterprise. To do this, compa-nies need to start even earlier to help develop industrial automation skills and capabilities. As a result, Moret an-nounced that Rockwell Automation has gifted $12 million to FIRST® Robotics, to encourage young students to get involved in engineering. “� at’s a lot of money — the big-gest gift they’ve ever received, and the biggest we’ve ever made,” he said.

Visit https://goo.gl/2mYVT5 to read more of Moret’s com-ments at the Automation Perspectives global media forum.

PSUG Shares The Connected Enterprise ExperienceAt the Rockwell Automation Process Solutions User Group, more than 780 process professionals from 26 countries gathered to learn about new technologies, process solutions and their peers’ and leading industry experts’ best practices in diverse process industries.

Process professionals were invited to eight hands-on labs, 22 technical sessions, 25 customer application ses-sions, and fi ve “Ask the Expert” sessions featuring results using the PlantPAx® distributed control system (DCS, www.rockwellautomation.com/go/plantpax6).

In addition, the company shared with attendees its own experience implementing � e Connected Enterprise, not-ing it has rationalized business processes and booked im-

provements in plant performance, supply chain effi ciency and customer service. Inventory, for example, dropped from 120 days to 82; on-time delivery improved from the mid-80s to 96%; and quality, as measured by defect rates, improved by 50%.

As a result of this transformation, John Genovesi, vice president and general manager of the Rockwell Automation Information Software and Process Business, told PSUG attendees, “Much of our focus now is on making our solu-tions easier to use, less expensive and easier to access.”

� is starts with analyzing the combinations of produc-tion and enterprise data � e Connected Enterprise off ers. “Suddenly we can get after warranty problems and relate them back to manufacturing issues,” Genovesi noted.

To read more on how the company’s own transforma-tive digitization is helping others build their Connected Enterprises, visit https://goo.gl/EsW9ru.

Attendees at PSUG also learned from other compa-nies about their process improvements. Flavor producer Givaudan shared their experience collaborating with Rockwell Automation Solution Partner Automated Con-trol Concepts, Inc. (ACC) (www.rockwellautomation.com/go/p-acc) to replace an aging DCS with no loss of production time. Learn more about how they carried out the migration at https://goo.gl/b6uM62.

Chemical company PCS Phosphate reported on their process improvement project that included moving and rebuilding an entire plant at a new site, consolidating and standardizing its controls, seamlessly integrating new hu-man machine interfaces and developing real-time reports.

“We used to have to wait days or weeks for reports, but now our real-time data is displayed immediately, and this system can even do some adjustments automatically,” noted David Klaas, senior electrical and controls engi-neer, PCS Phosphate. “� is means much better and more timely decisions. If you design a project like this right, it’s so worth it. In fact, this was a $16-million project, and it paid for itself in just nine months. We’re going to use PlantPAx on four other projects,” he added.

You can read more about the project at https://goo.gl/ZAKR52.

Mother Earth Brewing Co. provided another example of how process automation helped to achieve the com-pany’s goal of expanding into a new 40,000 sq. ft. facility while continuing to provide the fl exibility needed to main-tain and grow its eclectic collection of craft labels.

� e new system had to handle a wide variety of recipes. “We typically brew seven varieties of beer in a given week, and 60 or 70 varieties over the course of a year,” said head brewer Chris Baker.

“There’s been a lot of general conversation about the Industrial Internet of

Things (IIoT), and now we’re starting to make it real in applications such

as serialization, track and trace, compliance and scheduling,” — Blake

Moret, Chairman and CEO, Rockwell Automation



Along with recipe fl exibility, the automation system handles energy recovery, process-value-dependent rou-tines, and an innovative approach to clean-in-place (CIP).

Stone Technologies (www.rockwellautomation.com/go/p-stone), a system integrator and Rockwell Automa-tion Solution Partner, handled the automation, integrat-ing a PlantPAx-based system from Rockwell Automation that uses Sequencer Object for sequencing control, Batch Scheduler for scheduling and starting times, and separate parameter values for non-brew operations including CIP.

“� e CIP sequences use the same Sequencer Object instruction as the brew process, since all the control func-tions are the same,” said Ryan Williams, project manager for Stone Technologies.

Instead of a separate CIP skid, the system “uses the vessels themselves as washing machines,” Williams added. “� e process equipment has cycles to clean one, trigger the next, add caustic, etc. � ey can clean all four circuits at one time, which they couldn’t do with a CIP skid.”

Visit https://goo.gl/bDCkg5 to learn more about this project and lessons learned.

Partners Help Drive Connectivity� e 25th Automation Fair® event off ered no shortage of connectivity and industrial automation solutions from the Rockwell Automation PartnerNetwork. Encompass Product Partners, OEM Partners and Solution Partners demonstrat-ed many products and hundreds of solutions to enthusiastic show attendees. Read about some of the new technology in the “Product Focus” section on page 48 of this issue. In ad-dition, here are few popular technologies at the show.

Dialight (www.rockwellautomation.com/global/go/dialight), a new Encompass Product Partner and the fi rst

LED lighting supplier to join the program, explained to curious attendees how their products integrate and complement Rockwell Automation solutions. With built-in support for EtherNet/IP networking and the Common Industrial Protocol (CIP™), Dialight’s advanced light-ing controls can be tightly integrated with other systems within a facility, allowing site managers to consolidate control systems and simplify maintenance procedures.

For example, by integrating with Rockwell Automation, users have access to the company’s lighting network controls and can create their own logic and control systems using

“Much of our focus now is on making our solutions easier to use, less

expensive and easier to access.” — John Genovesi, Vice President and

General Manager, Rockwell Automation Information Software and

Process Business

Get highlights from 24 of the top exhibitors at the show in three-minute videos featuring some of the most innovative and reliable technologies featured at the event. Visit https://goo.gl/xbkPoZ to see demonstrations from member companies in the Rockwell Automation PartnerNetwork™ that include:

>> Watch Videos from the Automation Fair Event

• Advanced Energy• Aparian, Inc.• ASCO Numatics, Inc.• Badger Meter• Dialight• Endress+Hauser• EPLAN Software & Service• Fluke Corp.

• Grace Engineered Products, Inc.• HMS Industrial Networks• Hammond Power Solutions• IMPERX, Inc.• Laird• LinMot USA, Inc.• Littelfuse Inc.• Panduit

• Molex• Panduit Corp.• Revere Control Systems, Inc.• Southwire Company• Spectrum Controls Inc.• Stratus Technologies• Symantec Corp.• Tripwire



Dialight sensors and system status messages as input.

Tripwire, Inc. (www.rockwellautomation.com/global/go/p-tripwire), another new Encompass Product Part-ner, provides security and compliance solutions for enterprises and indus-trial fi rms. In addition to providing extended support for Rockwell Auto-mation Stratix™ networking devices, the company released the Tripwire Confi guration Compliance Man-ager (CCM), which interfaces with Rockwell Automation FactoryTalk® AssetCentre. � e new solution is designed to reduce industrial automa-tion system cyber security risks from external attacks, malicious insiders and human error, while also protect-ing critical infrastructure reliability, uptime and safety.

“Our integration with Rockwell Automation addresses the unique cyber security challenges associated with specialized and fragile opera-tional technology environments,” said Rekha Shenoy, vice president and general manager of Industrial Cyber Security for Tripwire. “With this integration, we are able to assess and monitor changes that can indi-cate a cyber attack without connect-ing to or communicating with PLC or control devices while maximizing uptime and improving security.”

Rockwell Automation revealed a new app, FactoryTalk TeamONE (www.rockwellautomation.com/global/go/ftteamone), for iOS and Android smartphones. � e app boosts team productivity by allowing users to collaborate and share knowl-edge, view live production diagnos-tics, interact with machine alarms, and troubleshoot devices. Teams that use the app could see reduced mean time to repair (MTTR).

By off ering near-instantaneous incident and device data, plant fl oor, engineering and IT workers can

Dialight sensors and system status messages as input.

The CDC estimates there are ap-proximately 3,000 deaths in the U.S. every year related to food safety illnesses,” said John Helferich, senior vice president of research and de-velopment for M&M Mars (retired), and Ph.D. candidate at MIT where he’s investigating how control theory can help to preserve the safety of our food supply.

“That would be like having 20 commercial plane crashes a year,” he said. “It’s quite a large number. An even bigger impact is that about 128,000 people end up in the hos-pital and 46 million suffer an illness. That puts food about in the middle of safety performance alongside health care.”

At the Food & Beverage Forum, Helferich discussed the Food Safety Modernization Act (FSMA) of 2011 and some opportunities he sees where process control can help improve the food safety landscape.

In the past, food safety was reactive: “Let’s stop this outbreak after it hap-pens,” Helferich said. With the new government regulations, it’s more of a proac-tive mode. The food industry has been working on preventing these problems for years. “The government regulations are just catching up with us,” he commented.

“A big change is the move from HACCP to HARPC,” he said, noting the move from hazard analysis and critical control points to hazard analysis and risk-based preventive controls. “With HACCP the only thing controlled was the critical control point, but maintenance, sanitation and training were assumed to be OK. With HARPC, all these items require the same control. It’s now about risk-based preventive controls. Prevent food safety issues from happening by training, proper operation and maintenance.”

With this new FSMA standard, data collection is a big opportunity that controls people and Rockwell Automation can help with, explained Helferich. “Collection of data off the floor, not just the temperature of the pasteurizer, but also training records and maintenance records — the data now needs to be collected and stored. Who’s going to do that, and how do you use the data? We need two years of record-keeping and the beginnings of a good track-and-trace system. Data in the food supply chain now needs to include intra-firm production records and inter-firm track and trace records. A problem from just a small ingredient supplier can effect a large amount of product. The data will need to tell what and where the ingredient went.”

Making use of the data to improve food safety performance is a big opportunity for controls. Focus on getting the data and improving feedback to the operators and mangers and be sure to store data to support record-keeping requirements.

Read much more at https://goo.gl/6opXpl.

>> Controlling Food Safety

“At the base, food safety is a control problem.”

— M&M Mars’ John Helferich.


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VG 342 SeriesAdditional Safety Components







Valve







(800) SMC-SMC1 (762-7621)


www.smcworld.com






• 3/4” NPT or Metric ports• 24VDC• Flow rate: 9Cv• Operating Pressure: 36 - 101 PSI• External pilot for low operating pressures• M12 connector for signal feedback• Monitoring through safety switch • Monitoring through safety switch• Operating frequency Max: 30 times/minute Min: 1 time/week• Lifetime: 900,000 cycles



VG 342 Series Additional Safety Components







Valve







(800) SMC-SMC1 (762-7621)


www.smcworld.com






• 3/4” NPT or Metric ports• 24VDC• Flow rate: 9Cv• Operating Pressure: 36 - 101 PSI• External pilot for low operating pressures• M12 connector for signal feedback• Monitoring through safety switch• Monitoring through safety switch• Operating frequency Max: 30 times/minute Min: 1 time/week• Lifetime: 900,000 cycles

TJ1702_FPA.indd 27 2/6/17 3:23 PM


collaborate as a team to quickly solve problems. From their smartphone, employees can choose from the variety of modules with the app to directly view information from devic-es, such as Allen-Bradley® PowerFlex® drives, or see the high-level health status of any EtherNet/IP device. � is information is shareable across the app’s collaboration and trouble-shooting modules with other trusted team members. Once issues are resolved, results can then be fl agged, saved and searched for the next time an incident arises.

� e app is a smart node. Rather than act as a client that connects to a server, the app’s device modules com-municate directly to devices on the network for live data viewing. When secure cloud access is available, the modules sync with other trusted team members.

Water Wastewater Forum: To Monitor or Not to MonitorFor expensive or critical equipment, periodic monitoring is not enough. “You may check it once a month, but as soon as you leave, you’re uncov-ered,” said Kim Chapman, senior project engineer, Hubbell, Roth & Clark, Inc.

At the 2016 Automation Fair® event, Chapman described in the Water Wastewater Industry Forum a recent pump and pipeline project to bring Lake Ontario water to Flint, Michigan, but centered on when and how to improve reliability by monitoring the condition of rotating equipment.

Varying loads, shocks, lubrication failure, bearing failure, equipment imbalance and excess wear can lead to rapid motor failures as well as destruction of fans, pumps and com-pressors. Continuously monitoring bearing temperatures and vibration

collaborate as a team to quickly solve problems. From their smartphone,

While the craft beer industry contin-ues to boom, many microbreweries are finding the scalability of process-es from small, manual pilot systems to larger ones — while maintaining quality, repeatability and consistency — is a key challenge. Minimizing water and energy usage is another key objective. Increasingly, brewers are looking to automation as a way to meet these challenges.

Steve Grundy, vice president of sales for Newlands Systems, saw an opportunity to advance the state of the microbrewery art when he joined the supplier of modular, scalable bre-whouse control systems. The 25-year-old company based in Abbotsford, BC, Canada has installed some 600 systems worldwide.

“We saw a way to take the tech-nology we are surrounded by here at Automation Fair and transform the way people think about brewing and the actual methods they use to drive better quality and consistency,” said Grundy at the Global Machine & Equip-ment Builders Forum.

Newlands’ solution for brewhouse automation is a midrange process con-trol architecture, typically with a CompactLogix™ control system.

It also uses Allen-Bradley 6181 integrated display computers with Facto-ryTalk® View SE. The drives are PowerFlex 525 AC drives on an EtherNet/IP communication architecture. It also includes smart instruments connected via EtherNet/IP, where possible.

“The brewhouse automation application software we’ve developed is flexible and can be used in a wide variety of configurations to provide better insights into your processes,” Gundy explained. “The application lowers automation and overall project costs.”

“In the end, whether it’s called The Connected Enterprise or the con-nected brewery, it’s really about how we use information to bring value and advantage to our customers,” noted Grundy. “Multiple sensors on assets can produce a wealth of information that, if contextualized or viewed in the right way, can provide insight to both the operator and manufacturer from a design standpoint. Use technology to harness that information to become smarter and to operate more effectively. Brew better beer and more of it at a lower cost.”

Read much more about this solution and the Global Machine & Equipment Builders Forum at https://goo.gl/mysuCt.

>> OEMs Address Need In Craft Brewery Market

“In the end, whether it’s called The Connected

Enterprise or the connected brewery, it’s really

about how we use information to bring value

and advantage to our customers,” — Steve

Grundy, Vice President of Sales, Newlands

Systems



gives early notice of pending failures, making users aware “so they can keep small problems from becoming big, expensive problems,” Chapman noted.

If a small pump fails, that may be OK if it’s easy to replace and not critical. “� at might cost $10,000,” Chap-man said. “But a big pump can cost $200,000, even half a million dollars. If you’re not there every day to look and listen, you need to monitor it.”

While monitoring systems costs much less now ($15,000 to $20,000) than in the past (about $50,000), they’re still not inexpensive. To understand when they’re worth the investment, add up the cost of periodic testing versus the risk in the “between” times. Compare the cost of repairs under planned outages against the cost of emer-gency repairs, including the costs of being out of service in lost production, sales and opportunity.

� e costs of equipment repair and replacement also can be highly variable. For example, if the normal cost of a repair is $15,000, the cost of repair under emergency con-ditions may be double, triple or more. Paying for special handling and shipping, as well as a special work schedule (24-hour, overnight, weekend) might add $30,000, for a total cost of $40,000, $50,000 or more.

Today’s integrated continuous monitoring systems pro-vide benefi ts to engineers, installers, owners and operators, as well as maintenance. For engineers, the systems are easy to specify and to detail the installation and integration requirements.

� ey also are easy to install and connect to motor con-trol centers (MCCs) and integrate to SCADA, supervisory controls and alarms. “� e monitoring system can be just another node on the SCADA network, making it easy to integrate, access and support,” Chapman noted.

Read more at https://goo.gl/PwMwr3.

Oil & Gas Industry Forum: Connectivity for Reliability As gas production and consumption rises, it’s critical that operations remain up and running. � is level of reliability means control systems need to off er data insight that allow operators to react to issues before they arise.

At the Oil & Gas Industry Forum, Brian Sloan, man-ager of automation and electrical engineering, for Trans-Canada’s Columbia Pipeline Group (CPG) shared how his company achieved 99.5% reliability with a connected control system.

“Lack of reliability was a major risk factor for ongoing operations,” Sloan said. “Our control system was outdated — we were buying components off of eBay. We needed a platform everyone could troubleshoot — to be able to

train them on one platform, not multiple platforms with multiple support contracts.”

� e company also wanted to rationalize data. “We had multiple control systems with multiple tag systems and databases, and multiple hands touching them,” Sloan said. “We needed data integrity.”

� e search for a solution led the CPG engineering team to standardize on a virtualized PlantPAx distributed control system (DCS) from Rockwell Automation. � e high-availability, scalable, modern DCS would share more information across facilities and up to the executive level, allow remote access and improve security.

“We confi gured the systems with visualization, histo-rian, domain controller and asset management,” Sloan ex-plained. At fi rst, the company used separate Dell servers, but the cabinets were fi lling up and management became concerned about long-term IT support. So they decided to implement virtualized industrial servers.

High-availability, virtualized servers from Rockwell Automation Encompass Product Partner Stratus Tech-nologies (www.rockwellautomation.com/go/p-stratus) reduced the physical space of the hardware and the likeli-hood of downtime due to hardware errors, and removed the need to procure hardware for each new application.

Each virtualized server runs multiple Rockwell Soft-ware® FactoryTalk applications (www.rockwellsoftware.com) including Historian, View Machine Edition, View Site Edition, AssetCentre and ViewPoint. ViewPoint al-lows operators to access the HMI applications from any location through a Web browser, so they can make real-time decisions.

Combined with historian software, the visualization capabilities of the system provide monitoring, reporting and data recording for immediate and future access. � e historian platform integrates with the corporate-level OSI-soft PI data warehouse system.

“Data is now valid, equipment is supported, and we can get replacement parts. And we can now make good operational decisions,” noted Sloan. “Before, we were able to project our needs for maintenance at the local level, but without a system-wide view, operating requirements would vary from what we expected. Now we can see into the fu-ture, and when we see a problem coming up, we can take equipment down and maintain it before it’s needed.”

Learn more about this project at https://goo.gl/8VmhG8.

Plan Ahead for 2017Be there in person this year. Plan now to attend the 2017 Automation Fair® event Nov. 15-16 in Houston!

gives early notice of pending failures, making users aware “so they can keep small problems from becoming big,

train them on one platform, not multiple platforms with multiple support contracts.”


THE JOURNAL | FEbRUARy 2017 WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL30

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Editor’s Note: This article is excerpted from the white paper, “Trends in Accelerating Performance Improvements with Modernized Operational Technology in the Industrial Sector,” from Stratus Technologies. Download the free, full white paper at https://goo.gl/gfESfy to learn how to prepare for and benefit from operations technology (OT) technological advancements; how extending the life of data-rich OT such as data historians, manufacturing execution systems (MESs) and SCADA systems, and programmable controllers can deliver higher return on assets (ROAs) and minimize future capital expenditures; and what is virtualization.

>> The drive to cut costs and avoid unplanned downtime remain primary operational goals in

industrial plants. A convergence of factors has created an opportunity for industrial firms such as manufacturing, oil and gas, chemical and water treatment companies to pursue both aggressively.

Although the pace of investment can be relatively slow in industrial automation, technological advances, econom-ic trends and market pressures have created an environ-ment in which plants are compelled to modernize OT to

help achieve maximum efficiency and minimum process interruptions. With the right OT strategy, industrial firms can optimize their processes and make the most of the Industrial Internet of Things (IIoT).

Outdated Automation SystemsSimply put, OT is getting old. The industrial sector is capital-intensive and traditionally uses equipment with long life cycles. The most recent prolonged economic downturn, coupled with the expectation of slower growth in many parts of the world, resulted in decreased levels of capital investment over the last five to seven years and delayed equipment upgrades.

Many organizations now rely on automation systems that are reaching the end of their useful lives. The total global installed base of those systems adds up to US$65 billion, according to ARC Advisory Group. Furthermore, the total installed base of automation systems that are more than 20 years old comes to $53 billion, according to ARC.

Organizations with outdated automation systems need to modernize their OTs to keep up with the pace of change, customer demands and business priorities, and to reduce the risk of critical failures and downtime.

The Pillars of Modernizing OTPlant operators should consider the following factors when further investing in automation systems:

• Be software driven. Modernized OT systems are controlled by software that dictates how the hardware operates. This leads to simpler management and more ef-ficient use of hardware resources.

• Provide efficient computing resources and virtual-ization. Historically, each industrial automation or other OT-related application has run on a separate server or even on a PC. With virtualization, one server can perform mul-tiple functions by running multiple applications. This cuts

Learn what to consider when updating operations technology to help maximize efficiency, boost agility, increase ROA and keep up with customer demands.

From Stratus Technologies

TIPS FOR MODER NIZINGAUTOMATION TECH NOLOGIES

Visit https://goo.gl/gfESfy and register to download the free, complete white paper, “Trends in Accelerating Performance Improvements with Modernized Operation-al Technology in the Industrial Sector,” from Rockwell Automation Encompass™ Product Partner Stratus Tech-nologies. You’ll learn how to prepare for and benefit from OT technological advancements; how extending the life of data-rich OT such as data historians, MESs and SCADA systems, and programmable controllers can deliver higher return on assets and minimize future capital expenditures; and what is virtualization.

>> Download the Free White Paper!

TJ1702_32_33_F5_stratuswp_v2.indd 32 2/6/17 2:30 PM

WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL FEbRUARy 2017 | THE JOURNAL 33

capital expenditures, because there are fewer servers to purchase, as well as operating expenses.

• Ensure redundancy and uptime in a virtualized world. Virtualization creates new critical points of failure. Managing server uptime is more important than ever, because a single server runs multiple or all OT functions. That’s why an auto-mation system that provides redundancy is so critical.

• Provide a single view of operations. A modernized solu-tion allows industrial companies to manage all OT opera-tions across systems from a single point of control.

• Deliver resilience. Technology managing OT must be able to keep pace with the speed of change in modern industry, handle retooling for new prod-ucts, support lean manufacturing, and deal with an increasing number of products and specifications.

• Be specifically built for the industrial sector. Solutions should be designed specifically for OT and an industrial environment, with all the requirements of that environment taken into account.

• Provide seamless integration. Servers and management systems should fit into a plant’s existing environment with no need for cumbersome custom integrations and no risk of data loss in the implementation process.

Plant operators don’t have go it alone when modernizing OT. The right partner vendor can provide knowledge and solutions to help generate maximum ROA.

Stratus Technologies, based in Maynard, Massachu-setts, is a participating Encompass™ Product Partner in the Rockwell Automation PartnerNetwork™. The company provides high availability and fault tolerant solutions to keep applications up and running.

Stratus Technologieswww.rockwellautomation.com/go/p-stratus

Rockwell Automation Encompass Partner Programwww.rockwellautomation.com/go/tjencompass

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>> Several years ago, I attended a safety presenta-tion at a Rockwell Automation on the Move

(RAOTM) show (www.rockwellautomation.com/global/events/raotm) in Michigan. The presenter introduced us to the Safety Maturity Index concept. This presentation realigned my thinking about machine safety as a cultural aspect of a company’s DNA, rather than as simply a tech-nical aspect of machine design and operation.

Since then, I’ve watched as individual companies and specific industry segments have taken steps along the continuum of safety maturity. I’ve also started to notice a

pattern emerge in terms of pneumatic system design. At first, companies tend to apply a single, overarching safety solution to the entire pneumatic system. As they come to understand better how to increase safety while also en-hancing productivity, the solutions become more nuanced.

Often, the key to achieving this next level of safety maturity is a return to some of the basic concepts of pneumatic system design, such as valve selection and component feature selection. This article reviews some of these basic concepts as they apply to a pneumatic system’s functional safety.

REMEMBER THE BASICS FOR PNEUMATIC SYSTEM SAFETY

Three primary methods commonly are applied to valve terminals to meet safety requirements and operational demands of various applications.

By Sean O’Grady, product manager, Festo Corp.

TJ1702_35_38_F6_festo.indd 35 2/6/17 3:03 PM


Valve and Valve Terminal ConsiderationsThree primary methods commonly are applied to valve terminals to meet safety demand requirements, and they can be combined to meet both the safety and operational demands of various applications. This list is by no means a comprehensive catalog of potential solutions, but it provides a starting point and covers many of the most common situations:

1. Safe removal of electrical power. Removal of electri-cal supply, generally with a Cat 3 or Cat 4 control architecture. In addition to assuring that valves do not respond to commands from the standard control program, this method can be used in conjunction with other methods to cause valves and their connected ac-tuators to respond to a safety demand in a specific way.

2. Safe removal of pilot pressure. Venting of a pneumatic valve terminal’s pilot section while the primary pressure remains applied. This can be an effective method of preventing unexpected startup, especially when used in conjunction with safe removal of electrical power.

3. Safe removal of primary pressure. Rapid venting of the entire pneumatic system or one of its zones. While this is an effective strategy for meeting the requirements of certain safety demands, this method often is not suitable for frequent safety demands as it consumes a great deal of energy and slows production.

Proper Component SelectionLet’s discuss some common concerns that pertain to each of these methods.

Safe removal of electrical power — When removing elec-trical power from a pneumatic system, hardware specifica-tion details become important. Ever since pneumatic valve terminals have started to incorporate on-board commu-nication adapters, it has become common to supply 24-V power twice: once for the valves and once for the commu-nications electronics.

Applying these products within Cat 3 or Cat 4 control architecture becomes problematic, as the 0-V connection is shared. If you switch the 0-V connection, you’ll lose your network communications.

When the safety demand has been resolved, the device must reestablish communication with the host, which can take up to 30 seconds in many cases, not to mention the nuisance alarm handling that is bound to go along with it.

Figure 1. These pneumatic power supply connections are used with Cat

3 or Cat 4 safety systems. They have separate 0-V connectors for valves

and for communications.

Figure 2. Both air-spring and mechanical-spring valves are used to control double-acting cylinders.

TJ1702_35_38_F6_festo.indd 36 2/6/17 3:03 PM


To solve this problem, make sure to choose a power connector with separate 0-V connections for the valves and the communications adapter (see Figure 1).

With certain valve terminals, it also is possible to cre-ate multiple voltage zones and pressure zones, allowing you to use a single valve terminal to control different safe zones within a machine. This feature allows machine builders to achieve multiple safe zones with reduced labor and material costs.

Special consideration also must be given when select-ing IO-Link valve manifolds because the power and communication connections reside within a single con-nector. While most industrial communication standards are the children of the various programmable logic controllers (PLC) manufacturers, IO-Link was brought to life from within the sensor community. As such, the original connector was specified only with three pins. As IO-Link output devices joined the fray, a second port specification was adopted that provides separate 24-V and 0-V connections for output power. This configura-tion is referred to as port type b.

It’s important to use valve terminals with port type b connections in conjunction with Cat 3 or Cat 4 control architecture.

Safe removal of pilot pressure — Especially when combined with the safe removal of electrical power, the safe removal of pilot pressure often is an effective way to satisfy an appropriate safety demand without venting the entire system. This is especially attractive in applications in which the safety demand happens frequently.

because the main system pressure remains engaged, proper valve selection becomes vital. Pilot supply switch-ing valves are available with a sensor to detect spool posi-tion, as well as integral pressure sensors to verify successful pressure removal in the manifold’s pilot galley. These two channels can work together to achieve a Cat 3 or Cat 4 control architecture.

When using this method, special attention must be paid to valve design. In Figure 2, both valves are single-solenoid, five-port, two-position pilot-operated valves of the type nor-mally applied to the control of double-acting cylinders. The

important difference is in how each achieves its “spring” function. The one on the left uses a traditional metal spring, while the one on the right uses an “air spring.”

With either valve, electrical power removal (without pilot pressure removal) will cause the valve to shift to the “normal” position, which applies pressure to port 2. In normal operation, you will notice no difference between these valves. In applications involving the safe removal of pilot pressure, the valve with the metal spring is the appropriate choice.

Figure 3 shows a double-solenoid valve. As there is no spring, pilot pressure removal simply duplicates the function of removing the electrical power. The same is true of three-position valves.

Safe removal of primary pressure — Depending on the hazards involved, it sometimes is necessary to remove all pressure from the portion of the machine involved in the safety demand. Depending on the performance level requirement, different valves are applied. For PLc demands, a single-channel dump valve may suffice. For PLd and PLe requirements, a more sophisticated, dual-channel valve is required.

When recovering from the safety demand in this cir-cumstance, it’s important to consider these key points:

Use a soft-start valve. The f low controls in pneu-matic systems are less effective during a system’s initial pressurization, so using a soft-start valve to pressurize the system gradually can help prevent machine dam-

Figure 3. The double-solenoid valve has no spring.

The key to achieving safety maturity is a return to some of the basic concepts of pneumatic system design.

TJ1702_35_38_F6_festo.indd 37 2/6/17 3:04 PM


age. Look for a safety dump valve that incorporates this feature.

Coordinate the recovery with the user program. Setting solenoids in the appropriate state before pressure is applied can help prevent diff erent actuators from crashing.

As these areas indicate, solutions are not intui-tive. It takes experience and knowledge of new tech-nologies, such as IO-Link, to grow in maturity.

My advice is to establish a long-term relationship with a pneumatics supplier that has the resources in terms of tools, personnel and technical expertise and an overall interest in collaborating on safety. � e OEM and machine end user gain an ally deeply interested in growing the safety maturity of internal teams, while the supplier acquires customers who value deeply the products and services off ered.

Mutually Benefi cial RelationshipsIn the end, everyone benefi ts. Systems are safer for opera-tors and maintenance personnel, less damage occurs to internal machine components and workpieces and machines produce quality products at high output.

Festo Corp. is a participating Encompass™ Product Partner in the Rockwell Automation PartnerNetwork™ program. Based in Hauppauge, New York, the company manufactures automation components that include safety valves, pneumatic valve control-lers, pneumatic valve interfaces and machine vision systems.

Festo Corp.www.rockwellautomation.com/go/p-festo

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Special attention must be paid to valve design.

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>> Flow measurement is a critical aspect of most pro-cessing applications. Accurate flow measurement

data affects both the effectiveness of operations and main-taining compliance with regulations. Also, a greater emphasis on sustainability is driving more manufacturers to closely monitor consumption of precious resources and byproducts. Another crucial concern is custody transfer, with increasing energy costs spurring the need for improved fiscal metering of high-value products.

because of these demands, it’s important to select the proper flow meter for optimal operation. Here, we’ll look at the most frequently used measurement technologies and pro-vide some pointers for picking the most appropriate device.

Common ChoicesLet’s start by reviewing the most common and current measurement technologies and their advantages and disadvantages:

Coriolis meters contain a vibrating tube in which a fluid flow causes changes in frequency, phase shift or amplitude. Circuitry in the devices then converts this signal into an output that’s strictly proportional to the actual mass flow rate. This is in contrast to thermal mass flow meters, which depend upon the physical properties of the fluid.

One important feature of a Coriolis flow meter is its ability to directly measure fluid mass with a high degree of accuracy over a range of temperatures. Its unobstructed open-flow design is suitable for viscous nonconductive fluids that are difficult to measure with other technologies. With no internal moving parts, a Coriolis meter requires a minimum amount of attention once installed. However, such devices sometimes

are considered too sophisticated, expensive or unwieldy for certain applications.

Differential pressure (DP) meters measure the pres-sure differential across the meter and extract the square root. They have a primary element that causes a change in kinetic energy, creating DP in the pipe, and a secondary element that measures the DP and provides a signal or read-out converted to the actual flow value.

DP meters are versatile instruments that employ a well-un-derstood measuring technology not requiring moving parts in the flow stream. Viscosity changes don’t affect the devices greatly. However, they have a history of limited accuracy and turndown, and complex installation requirements.

Electromagnetic meters employ Faraday’s law of electromagnetic induction; a conductor moves through a magnetic field, inducing voltage. The liquid acts as the conductor, with energized coils outside the flow tube creat-ing the magnetic field. The produced voltage is directly proportional to the flow rate.

These meters will measure any conductive fluid or slurry, including process water and wastewater. The devices provide low pressure drop, high accuracy, large turndown ratio and excellent repeatability. They have no moving parts or flow obstructions, and are relatively unaffected by viscosity, temperature and pressure when correctly specified. Electromagnetic meters tend to be heavy in larger sizes and might be prohibitively expensive for some purposes.

Thermal mass meters use a heated sensing element isolated from the fluid flow path. The flow stream con-ducts heat away from the sensing element, with the rate directly proportional to the mass flow rate. The meter’s

PROPER FLOW METERHOW TO PICK THEBy Brian Kettner, product manager, Badger Meter

TJ1702_40_44_F7_badger.indd 40 2/7/17 11:51 AM


electronics package provides a linear output directly proportional to mass flow.

Thermal mass meters have a relatively low purchase price. They’re designed to work with clean gases of known heat capacity, and some low-pressure gases not dense enough for Coriolis meters to measure. The main disadvantage is low-to-medium accuracy, although their capabilities have improved in recent years.

Turbine meters contain a freely suspended rotor with vanes that rotate at a rate proportional to flow velocity. A sensor/transmitter detects the rotational rate of the rotor; the faster the fluid moves, the more pulses generated. The trans-mitter processes the pulse signal to determine the flow of the fluid in either forward or reverse direction.

Turbine meters incorporate a time-tested measuring prin-ciple, and are known for high accuracy, wide turndown and repeatable measurements. They produce a high-resolution pulse-rate output signal proportional to fluid velocity and volumetric flow rate. Turbine meters are limited to clean fluids only. Use of ceramic journal bearings largely has ad-dressed bearing wear — a common concern with this type of device. As a mechanical meter, turbines require periodic recalibration and service.

Impeller meters are frequently used in large-diameter water distribution systems. These devices insert a paddle wheel perpendicularly into a process stream. The number of rotations of the paddle wheel is directly proportional to the velocity of the process.

Their advantages include direct volumetric flow measure-ment (often with visual indication), universal mounting, fast response with good repeatability, and relatively low cost. However, their performance suffers in applications with low

fluid velocity; the meters also are sensitive to flow profile. They suit clean, low-viscosity media.

Ultrasonic meters come in two types: transit time and Doppler. both designs will detect and measure bidirectional flow rates without invading the flow stream. They can handle corrosive liquids as well as gases, and are insensitive to chang-es in temperature, viscosity, density or pressure. A clamp-on ultrasonic meter is ideal for troubleshooting, diagnostics and leak detection.

Ultrasonic meters have no moving or wetted parts, suffer no pressure loss, offer a large turndown ratio, and provide maintenance-free operation. However, precision becomes much less dependable at low flow rates. Un-known internal piping variables can shift the flow signal and create inaccuracies.

Variable area meters are inferential measurement devices consisting of two main components: a tapered metering tube and a float that rides within the tube. The float position — a balance of upward flow and float weight — is a linear func-tion of flow rate. Operators can take direct readings based on the float position within transparent glass and plastic tubes.

Simple, inexpensive and reliable, these meters are appropri-ate for many applications. However, they must be calibrated for viscous liquids and compressed gases. Furthermore, they offer limited turndown and relatively low accuracy.

Vortex meters make use of a principle called the von Kármán effect, where flow alternately generates vortices when passing by a bluff body (a piece of material with a broad flat front that extends vertically into the flow stream). Flow veloc-ity is proportional to the frequency of the vortices. Flow rate is calculated by multiplying the area of the pipe by the velocity of the flow.

PROPER FLOW METERHOW TO PICK THE This thorough guide covers common technologies used in flow instruments and key factors to consider

when selecting a meter for optimal process operation.



Because these meters have no moving parts subject to wear, they don’t require regular maintenance. However, they only can measure clean liquids. � e devices are well suited for measuring gas emissions produced by wastewater. � e meter’s obstructions in the fl ow path could lead to pressure drop.

Oval gear meters use a positive displacement (PD) me-ter design where fl uid enters the inlet port and then passes through the metering chamber before exiting through the outlet port. Inside the chamber, the fl uid rotates the internal gears. Each rotation displaces a specifi c volume of fl uid. As the gears rotate, a magnet on each end of the gear passes a reed switch, which sends pulses that a micropro-cessor translates into a fl ow rate shown on an LED display.

� e latest oval gear meters directly measure actual volume. � ey feature a wide fl ow range, minimal pressure drop and extended viscosity range. � is design off ers easy installation and high accuracy, and measures high-temperature, viscous and caustic liquids with simple calibration.

Nutating disc meters, most commonly used in water metering applications, feature a disc attached to a sphere mounted inside a spherical chamber. As fl uid fl ows through the chamber, the disc and sphere unit wobble or “nutate.” � is causes a pin, mounted on the sphere perpendicular to the disc, to rock. Each revolution of the pin indicates a fi xed volume of liquid has passed. Meters with aluminum or bronze discs can monitor hot oil and chemicals.

� ese meters have a reputation for high accuracy and repeatability. However, viscosities below their designated threshold adversely aff ect performance.

Key Selection FactorsTypically, fl uid characteristics (number of phases, viscosity and turbidity), fl ow profi le (laminar, transitional or turbu-lent), fl ow range and accuracy requirements are important considerations in determining the right fl ow meter for a measurement task. Additional considerations such as mechanical restrictions and output-connectivity options also might impact the choice. Key factors in meter selection include the following:

Process media. Whether the fl uid is liquid, gas or multi-phase infl uences the suitability of a particular device for the service. Diff erent fl ow meters are designed to operate best with certain fl uids and under specifi c operating conditions.

Measurement type. Do you need a mass or volumetric fl ow measurement? While volumetric readings are convert-ible into mass measurements given an accurate density, volumetric measuring devices such as variable area and tur-bine meters can’t distinguish density-altering temperature or pressure changes. So, mass fl ow measurement would require additional sensors for these parameters and a fl ow computer to compensate for the variations in these process conditions.

Flow rate information. It’s crucial to determine if continuous or totalized fl ow rate data are needed. A typical continuous fl ow measurement system consists of a primary fl ow device, fl ow sensor, transmitter, fl ow recorder and totalizer.

Desired accuracy. � e diff erence between on- and off -specifi cation product often depends upon fl ow meter accuracy. � is is specifi ed in percentage of actual read-ing, calibrated span or full scale. It normally is stated at minimum, normal and maximum fl ow rates.

Application environment. Decide whether the low or high fl ow range is most important for a metering applica-tion; this information will help in sizing the correct in-strument for the job. Pressure and temperature conditions are equally important process parameters. You also should consider pressure drop in fl ow measurement devices, espe-cially with high-viscosity fl uids.

Fluid characteristics. You must pick a meter compat-ible with the fl uid and operating conditions. Many plants handle abrasive or corrosive fl uids that move under aer-ated, pulsating, swirling or reverse-fl ow conditions. � ick and coarse materials can clog or damage internal meter components, hindering accuracy and resulting in frequent downtime and repair.

Installation requirements. Planning a fl ow meter in-stallation starts with knowing the line size, pipe direction, material of construction and fl ange-pressure rating. Iden-tify possible complications from equipment accessibility, valves, regulators and available straight-pipe-run lengths.

Power availability. For hazardous areas, pneumatic instrumentation typically was used to avoid bringing in a power source that might cause an explosion. Today’s in-stallations normally call for intrinsically safe instruments; these rely on safety barriers that limit current to prevent any potential spark.

The need to recalibrate a fl ow meter depends upon how well the instrument fi ts a particular application.



Turbine fl ow meters off er an advan-tage in environments where a power source isn’t available because they don’t require external power to provide a local rate/total indicator display for a fi eld application; the devices instead rely on a battery-powered indicator.

Necessary approvals. Plants must comply with relevant standards and regulations for fl ow measurement equipment used in hazardous loca-tions. � ese include: FM Class 1 Divi-sion 1, Groups A, B, C and D; and FM Class 1, Zone 1 AEx d (ia) ia/IIC/T3-T6. Standards such as the Mea-suring Instruments Directive in the European Union apply to fi scal- and custody-transfer metering for liquids and gases. In terms of environmental emissions, industrial fl ow meters must meet the Electromagnetic Compat-ibility Standards EN55011:1992 and EN61326-1:1997.

Output/Indication. Decide whether measurement data are needed locally or remotely. For sending data for remote indication, the transmission can be analog, digital or shared. � e choice of a digital communications protocol such as HART, Foundation Fieldbus or Modbus™ also fi gures into this decision. In a large plant, fl ow readings typically go to an automation system.

Other Important IssuesBecause higher accuracies and broader capabilities in fl ow meters cost more, determine what you actually need. Evaluate process conditions, including fl ow rates, pressure and temperature, and operating ranges to fi nd a meter suited to the specifi c application. Sacrifi cing features for cost savings or opting for a lower-priced alternative that would be applied outside of its capabilities can be false economies.

In addition, always examine long-term ownership costs. A fl ow meter with a low purchase price might be very expensive to maintain. Alterna-tively, a meter with a high purchase

price might need very little service. Lower purchase price doesn’t always represent better value.

Generally speaking, fl ow meters with few or no moving parts require less attention than more-complex

instruments. Meters incorporating multiple moving parts can malfunction due to dirt, grit or grime present in the process fl uid. In addition, impulse lines needed with some meters can plug or corrode, and units with fl ow dividers

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and pipe bends sometimes suff er from abrasive-media wear and blockages. Changes in temperature also aff ect the inter-nal dimensions of the meter and require compensation.

� e need to recalibrate a fl ow meter depends upon how well the instrument fi ts a particular application. If the ap-plication is critical, check meter accuracy at frequent intervals. Otherwise, recalibration might not be necessary for years for non-critical applications and ones where conditions don’t vary.

No matter the chosen technology, overall system accu-racy won’t exceed that of the equipment used to perform the meter calibration. � e most precise fl ow calibration systems on the market employ a PD design. � is type of calibrator, directly traceable to the U.S. National Institute of Stan-dards and Technology via water draw validation, provides total accuracy of at least 0.05%.

All meters are aff ected to some extent by the medium they monitor and how they’re installed. Consequently, their performance in real-world conditions often will diff er from the reference conditions under which they were calibrated. Electromagnetic meters provide for the widest fl ow range, while turbine meters usually are the best choice for the

highest short-term repeatability. Despite their high initial cost, Coriolis meters are ideal for measuring particularly vis-cous substances and wherever readings of mass rather than volume are required.

Choose WiselyKnowing basic fl ow-measurement techniques and meter options, and consulting with a knowledgeable instrumen-tation supplier in the early stages of a project, can help achieve successful fl ow meter operation.

Badger Meter, based in Milwaukee, is a participating Encompass™ Product Partner in the Rockwell Automation Part-nerNetwork™. � e company manufactures fl ow meter products, Research Control valves, actuators, sensors and monitors. In addition to water utilities, the company serves industrial and commercial markets, including energy and petroleum; food and beverage; pharmaceutical; chemical; HVAC; process; wastewater; aerospace; and automotive.

Badger Meterwww.rockwellautomation.com/go/p-badgermeter

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INCO ENGINEERING REMOTELY MONITORS EQUIPMENT Mining industry OEM designs customized hoists with safety and reliability in mind, and monitors its equipment around the globe from a single location.

>> Iron ore, gold, coal, potash and other metals

and minerals have been important re-sources since prehistoric times. How-ever, the methods of mining those resources have drastically improved. Mining companies now use hoisting equipment to move materials and personnel quickly from underground to the surface — typically between a half mile to a mile deep.

As technological capabilities grow, mining company managers want to become even more productive and competitive globally. They want to run hoists continuously without stopping for unplanned maintenance, and increase the load size brought up by the hoists. However, safety and reliability are a major concern. A hoist’s skip can move up to 60 feet per second and needs to stop within a predetermined position without causing any issues.

Rockwell Automation OEM Partner INCO Engineering designs and builds modern mining hoists and complete systems for vertical and inclined transport in mines. The Prague-based company designs customized equipment for mining companies around the globe — in-cluding in Czech Republic, Poland, Slovakia, Russia, Kazakhstan, Turkey and India — and is growing in the

United States and Canada. Custom-ers’ targeted resources include coal, iron ore, uranium, copper, potash, silver and gold.

INCO’s hoists are technological-ly advanced behemoths, reaching up to two stories high. The OEM works with customers to design and build them to mine require-ments; while the hoist specifics may change from customer to customer, the biggest constant is the need for safety and reliability. INCO builds layers of control redundancy into each hoist system to help minimize the risk of downtime.

Control ComponentsThe company uses Allen-bradley® PowerFlex® 750 AC drives (www.rockwellautomation.com/go/tjpf700) and high-voltage Power-Flex 7000 drives (www.rockwell automation.com/go/tjpf7000) from Rockwell Automation. The Power-Flex 7000 active front-end rectifier provides speed control.

An Allen-bradley CompactLogix™ 1769-L33ER programmable automa-tion controller (www.rockwellauto mation.com/go/tjcompactlogix) fea-tures an integrated platform for control and motion execution, communicates

OEM PARTNER PROFILE

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over an Ethernet network, and can be confi gured in a single programming environment. � is provides INCO’s customers with fewer spare parts to maintain, while the control platform’s openness helps to ease integration with third-party components.

� e control system supports a device-level ring net-work topology, helping users maintain communications if a fault occurs. Cabling is reduced due to an applica-tion of distributed inputs and outputs. An Allen-Bradley PanelView™ Plus 6 human-machine interface (www.rockwellautomation.com/go/2711) provides a user-friendly interface between the machine and operator monitoring the hoisting process.

Remote MonitoringModern hoists can operate without any supervision or operators. Typically, operators monitor the automatic operations from an on-site control cabin. However, more companies now see the value of remotely monitor-ing operations.

With that in mind, INCO developed and off ers Transdatic, an advanced remote-monitoring system that continuously monitors conditions of selected equipment, and data is securely transferred to INCO’s central service center. If an issue occurs, INCO staff can notify users im-mediately — reducing the customers’ maintenance costs. Staff also can analyze the most frequent faults, and help users make equipment and process adjustments to prevent further occurrences. � e system can be implemented with hoists anywhere in the world from the service center in the Czech Republic.

INCO Engineering, a participating Rockwell Automation OEM Partner, is a Czech Republic-based global provider of transport containers and lift mechanisms for the mining industry. � e company focuses on technology for vertical, inclined, and horizontal transport, primarily in underground mines, but also in open-pit mines.

INCO Engineering S.R.O.www.rockwellautomation.com/go/inco

integratintegratintegratintegratintegratIT-OT Data

Softing Inc.865-251-5252 [email protected] www.softing.us

Keep your critical data securely up to date and accessible.

Keep your production flowing smoothly and efficiently with tManager®.

Cut your installation and maintenance costs. One tManager module efficiently handles

all your data transfer needs.all your data transfer needs.

Call for a quote or aCall for a quote or a tManager demonstration.demonstration.

• Fast & Friendly:Fast & Friendly:“Configure & Go” “Configure & Go” set-up and updates – set-up and updates – online help – unlimitedonline help – unlimitedinstallations of configinstallations of configsoftware

• Flexible: Hardware Hardware based solution with based solution with bi-directional databi-directional dataexchange betweenexchange betweenmultiple database andmultiple database andcontroller typescontroller types

• Robust: Communications Communicationsvia ControlLogix®via ControlLogix®backplane or Ethernet.backplane or Ethernet.Extensive logging -Extensive logging -Nonvolatile ConfigurationNonvolatile ConfigurationStorage

• Secure: Access only via Access only viaGUI, Not a PC – no forcedGUI, Not a PC – no forcedOS updates; no virusesOS updates; no virusesnor malware

INCO builds layers of control redundancy into each hoist system to help minimize the risk of downtime.

TJ1702_45_46_oemprofile.indd 46 2/6/17 3:16 PM


Direct Replacement for 1746-HSTP1 (SLC 500)

AMCI’s 3501-HSTP1 is the direct replacement for the Allen-Bradley® 1746-HSTP1 motion module (for SLC™ 500) which has been discontin-ued. AMCI’s 3501-HSTP1 module shares identical features, program-ming and performance, guaranteed. AMCI specializes in PLC-based motion control and is approved to sell the direct replacement module. Allen-Bradley licensed technology ensures 100% compatibility. Contact AMCI today for price and availability at 860-516-8771. https://goo.gl/l75rNJ

ADVANCED MICRO CONTROLS INC. (AMCI)

Process Diagnostic & Optimization Technology

Is your goal to optimize production? PlantESP actively monitors control loop per-formance on a plantwide basis. It utilizes existing process data to uncover mechani-cal issues, PID tuning opportunities and more. PlantESP identifies issues, isolates root causes and recommends corrective actions. PlantESP’s powerful diagnostics and intuitive design make it easy to improve production throughput and efficiency. Customizable reports and alerts keep you informed of all performance changes. Contact us at (860) 872-2920 ext. 1602 or visit www.controlstation.com/plantesp.

CONTROL STATION INC.

System Integration Just Got a Whole Lot Easier

HMS provides a family of network connectivity prod-ucts based on the Anybus technology, which offers full integration into Rockwell Automation ControlLogix® and CompactLogix™ PLC controllers on EtherNet/IP to seamlessly communicate with Modbus, PROFIBUS, DF1 and serial devices. www.encompass.hms-networks.com/home

HMS INDUSTRIAL NETWORKS

WITTENSTEIN alpha V-Drive Basic Worm Gear

The V-Drive Basic worm gear is designed for price sensitive applications with no high-end requirements for maximum torsional backlash. Available with hollow or solid shaft, and a total of five different reduction ratios. At just 7.4 kg and 12 kg respectively, the lightweight V-Drive helps save energy when the gearhead is used in moving machine axes. www.wittenstein-us.com

WITTENSTEIN

Excel Reports and Forms for Industry

Finally, a reporting solution that gives the information you need, in the form you want, with absolutely no programming. With XLRe-porter, you use Excel as your “design studio,” complete with our easy-to-follow FastStart wizard. Your reports are ready within minutes in Excel, Web, PDF and email. The product is compatible with RSLinx®, RSView®, FactoryTalk® View, PanelView™ Plus, OPC, OPC-HDA, databases and much more. For more information, contact us at (508) 520-9957 or [email protected]. Download your free evaluation copy from www.SyTech.com.

SYTECH INC.

EtherNet/IP Process Video Recorder

IMPERX’s EtherNet/IP™ Process Video Recorder (EIPVR) is an event-recording sys-tem that captures high-speed video when you need it. This product is EtherNet/IP-conformance tested, compatible with IEEE 1588 and uses Power-over-Ethernet cabling for a simple installation. EIPVR records up to 60 seconds of video at 250 fps, automatically saves video to a server and plays video for quick feedback. EIPVR is triggered via EtherNet/IP, is ODVA tested and approved, and is compatible with EtherNet/IP devices. http://imperx.com/rockwell-encompass-partner-program

IMPERX

ENCOMPASS SHOWCASE

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>> Enterprise-Ready Connectivity PlatformRockwell Automation Encompass™ Product Partner Kepware Technologies has launched KEPServerEX Version 6 software. Enhancements include a new method for remote configuration, additional languages that support critical industrial automa-tion markets, and significant updates to the user interface and licensing experience.

KEPServerEX is an industrial connectivity platform that uses OPC and IT-centric communication protocols to provide a single source of industrial automa-tion data to enterprise applications. The platform offers a library of more than 150 device drivers, client drivers and advanced plug-ins that allow connectivity to thousands of devices and other data sources.

The new REST-based API allows off-site users to remotely apply program-matic changes to the configuration via third-party client applications. Users can easily configure multiple KEPServerEX instances from their enterprise software, improving security and collaboration between operations and IT.

Native development of core OPC UA technology provides improved perfor-mance, enhanced diagnostics, and continued OPC UA functionality enhancements.

Kepware Technologieswww.rockwellautomation.com/go/p-kepware

The Proline 300/500 smart Coriolis mass and electromagnetic flow instruments from Rockwell Automation Strategic Alliance Partner Endress+Hauser simplify installation, speed commissioning, and streamline operation and maintenance. The instruments are optimized for maximum safety, enhanced measure-ment quality and device accessibility and availability. They also address the need for better digital communications and flow devices that can be used by less-experienced staff.

The series maintains the same dimensions of pre-existing sensors for easy drop-in replacement. Equipped with aluminum, hygienic stainless-steel or cast stainless-steel housings, the instru-ments offer flexibility for all environments including those with high temperatures, corrosive fluids, or hygienic and sterile requirements. In the 300 series, the com-pact transmitter mounts integrally to the sensor, while the 500 series provides remote accessibility of the transmitter from sensors.

Redundant, traceable references help avoid undetected drift in measurement. The instruments let users access signals and data

through HMIs to match plant preferences. Integration into optical displays permits access from handhelds like tablet PCs or smart phones from a common web browser. Each method allows fast

commissioning, in-situ device verification during operation, access to diagnostics and automated on-board data storage.

The instruments include Heartbeat Technology with remedy-based diag-nostics, monitoring and verification for satisfying regulatory, contractual, quality, safety or fiscal requirements. These di-agnostics tell users on the display or any HMI what steps are needed to resolve the event faster and safer. Its Heartbeat Verification allows device verification with audit safe documentation within 5 minutes or less.

To automatically protect data storage, a HistoROM onboard event logbook and data logger can be accessed locally or

remotely to store operating, calibration and verification data.

Endress+Hauser Inc.www.rockwellautomation.com/go/p-eh

>> PRODUCT SPOTLIGHT

Flow Meters with Smart Communications

PRODUCT FOCUS PRODUCT FOCUS

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>> Bluetooth Industrial Ethernet CradleThe Zebra STB3574 (IE) Industrial Ethernet cradle from Encompass™ Product Partner Zebra Technologies is designed for use with the company’s LS/DS 3578 rugged scanners and con-nects via Bluetooth. The cradle and scanner suit industrial use cases that require barcode scanning such as error proof-ing, track and trace, sequenc-ing, shipping and receiving and direct part marking.

It supports EtherNet/IP, allowing direct connection of barcode data to Rockwell Automation controllers. EDS and GSD device definition files are available for PLC application development. The device is easily configured through Zebra industrial Ethernet utility software and provides full battery charge in 4.5 hours.

Zebra Technologieswww.rockwellautomation.com/go/zebra-technologies

>> Cyber Security Solution for Industrial AutomationThe Tripwire Configuration Compliance Manager (CCM) from Encom-pass™ Product Partner Tripwire, Inc., now supports ANSI/ISA-62443, a global standard for securing industrial automation systems, controllers and associated networking equipment configurations.

Tripwire CCM can reduce cyber security risks from external attacks, mali-cious insiders and human error while protecting critical infrastructure reliability, uptime and safety of industrial automation and manufacturing environments.

The software is a light touch, agentless auditing system for a range of enterprise IT and OT devices including routers, switches and gateways. It delivers a single prioritized view of compliance and security risks across IT and OT environments, making it possible for organizations to evaluate enterprise-wide security and compliance risks.

The system allows engineers and cyber security personnel to audit indus-trial automation networks and controllers for secure and approved configu-rations. It identifies unauthorized changes, configuration hardening errors and security vulnerabilities and provides prioritized remediation guidance to reduce risks without affecting operational availability, reliability or safety.

The software can be layered on top of a standard implementation of FactoryTalk® AssetCentre from Rockwell Automation for greater visibility into industrial automation applications.

Tripwirewww.rockwellautomation.com/global/go/p-tripwire

>> PRODUCT SPOTLIGHT

FactoryTalk TeamONE App

The Rockwell Automation FactoryTalk® TeamONE app, for iOS and Android smartphones, boosts team productivity by helping users collaborate and share knowledge, view live production diagnostics, interact with machine alarms, and troubleshoot devices.

From their smartphone, employees can view information from devices, such as Allen-Bradley® PowerFlex® drives, or see the high-level health status of any EtherNet/IP device. This information is shareable across the app’s collaboration and troubleshooting modules with other trusted team members. Once issues are resolved, learnings can then be flagged, saved and searched for the next time an incident arises.

The app is a smart node. Rather than act as a client that connects to a server, the app’s device modules communicate directly to devices on the network for live data viewing. When secure cloud access is available, the modules sync with other trusted team members.

FactoryTalk TeamONE Free Edition is available now and includes eight modules: Incident, Device Health, Teamboard, Knowledgebase, Connect, Pinboard and Chat, Connect and Trend. It can be downloaded free from the Google Play or Apple app stores.

A Standard Edition will be offered in 2017 on a yearly user-based subscription. It will provide an ad-ditional alarms module, multiple team logins and other features. Teams with a mix of free and subscription ver-sions are not hindered from seamlessly collaborating.

FactoryTalk TeamOnewww.rockwellautomation.com/global/go/ftteamone

PRODUCT FOCUS PRODUCT FOCUS



>> Cloud-Native Remote Access PlatformProSoft Connect, a secure, cloud-native platform with an intuitive Web interface from Encompass™ Product Partner ProSoft Technology features EasyBridge technology that connects your PC to the remote network. It also allows software tools such as RSLinx®, Studio 5000®, Unity, and TIA Portal to work without routing. This helps users browse their remote network for devices, making it as easy as having their PC plugged right into the remote switch.

The first product to use this service is the ICX35-HWC Industrial Cellu-lar Gateway. Users can get remote access to their ICX35 gateways from anywhere. 4G LTE connectivity with fallback to 3G helps prolong service life and provide clear coverage worldwide.

ProSoft Technologywww.rockwellautomation.com/go/p-prosoft

Advanced Micro Controls, Inc. (AMCI) 34, 47

Apex Dynamics Inc. 11

Control Station 47

Endress+Hauser, Inc. 3

Hammond Power Solutions, Inc. 14

Helm Instrument Co. Inc. 44

HMS Industrial Networks Inc. 10, 12, 47

IMPERX, Inc. 21, 47

Itoh Denki USA, Inc. 38

Molex 6

ProSoft Technology, Inc. 52

Rockwell Automation Connected Enterprise 51

Rockwell Automation Safety Systems 39

Rockwell Automation Solution Partner Program 13

Spectrum Controls, Inc. 18

Softing 46

Sytech Inc. 47

SMC Corporation 27

Tolomatic 20

Teledyne DALSA 30, 31

WITTENSTEIN, Inc. 2, 47

Zebra Technologies Corp. 15

ADVERTISERS INDEX

>> Absence of Voltage TesterRockwell Automation Strategic Alliance Partner Panduit Corp. introduces the VeriSafe absence of voltage tester that simplifies the voltage verifica-tion process through automation. This helps reduce risk of worker expo-sure to electrical hazards by verifying the absence of voltage before equipment is accessed.

The tester is designed to help determine an electrically safe environment in a fraction of the time required by hand-held portable test instruments. Once installed, a push of a button allows qualified electri-cal workers to see an active visual indication when the absence of voltage is confirmed. This provides a way to safely, efficiently and reliably verify the absence of voltage before accessing potentially dangerous electrical equipment.

The tester simplifies the process for easier NFPA 70E compliance, and reduces testing procedure time and complexity to improve produc-tivity. It’s designed to comply with UL 1436 and UL 508 standards.

Panduit Corp.www.rockwellautomation.com/go/p-panduit


Download the Connected Enterprise whitepaper at www.rockwellautomation.com /connectedenterprise

Connect your Enterprise. Help secure your future.The world’s leading manufacturing and industrial companies protect their intellectual property and brand image with a safe and secure operating environment – helping to ensure regulatory compliance and reducing exposure to security risks.

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. AD2014-43-US.* McAfee and CSIS In the Dark: Crucial Industries Confront Cyber attacks 2011.

AlertConnected Enterprise

of organizations say that their current security programs are inadequate*

70%

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