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A&D - InterviewJason UrsoVP & CTO Honeywell International (p.34)

A&D - InterviewDr Oliver VietzeCEO & Chairman Baumer Group (p.32)

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VOL 07 | APR-MAY 2014 | ` 100

www.AandD24.in

Better process-to-product managementEfficient Manufacturing

Automation & DrivesA U TO M AT I O N & D R I V E S

A cOMpREhENSIVE AppROAch TOwARDS AUTOMATION

FOcUS chemical & process P. 42, 48

ROUND-TABLE Revamping automation education & training P. 36

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NI Systems (India) Private Limited Phone: 1800 103 9449 (Toll Free) Email: [email protected]

>> Accelerate your productivity at ni.com/industrial-control-platform

©2012 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 07926

Lowering cost, increasing productivity, and shortening design times are just some

of the challenges industrial engineers face. The graphical system design approach

combines productive software and reconfigurable I/O (RIO) hardware to help you

meet these challenges. This off-the-shelf platform, customizable to solve any control

and monitoring application, integrates motion, vision, and I/O with a single software

development environment to build complex industrial systems faster.

NI LabVIEW system design software offers ultimate flexibility through FPGA programming, simplifies code reuse, and helps you program the way you think–graphically.

Unbeatable Control,Precision, and Flexibility

ed i tor i al

Global competition, complexity, speed, accuracy, regulatory compliance, and customer demands are pressurising manufacturing companies to improve operating performance and at the same time keep the costs low. While automation has clearly been the perceived means to improve operating performance keeping the costs low, research indicates that implementation has been slow, and many times even claimed successes remain functionally fragmented. Many companies struggle even with internal connectivity among various functions, forget about end-to-end supply chains.

What is needed to realise the full benefits of automation is to transform the fundamentals of functional connectivity and supply chain management and usher in new waves of collaboration, integration, optimisation, and communication across industries. It is also necessary to gain an understanding of the market drivers and transformational outcome of technological change.

The Cover Story in this issue talks on the technological change in automation requirements and the considerations to be taken into account while adopting new-age automation technologies or upgrading to new automation systems.

I am happy to inform you that, with this issue, A&D India is entering into its 7th year of operation. We hope that you have enjoyed reading the magazine, and will do so in future as well, and you will continue to support our efforts to help us maintain the high standards. We would like to thank the members of our editorial advisory board, our contributors, associates and the advertisers who supported us in our success route.

Best wishes!

Shekhar JitkarPublisher & Chief [email protected]

Maintaining high standards!

3a& d i n d i a | A p r-M a y 2014

MICRO-EPSILON | 94496 Ortenburg / GermanyPhone +49 85 42/168-0 | [email protected]

Representative for India:IPS Integrated Process Systems | 600 004 ChennaiPhone +91 44 24981786 | www.ipsindia.in

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Anup WadhwaDirector – AIA (Automation Industry Association)

P V SivaramMD – B&R AutomationMember – AIA

Anant MaheshwariManaging Director Honeywell Automation India

Ganapathiraman GVice President & GM (South and South-East Asia)ARC Advisory Group

Ravi AgarwalDirector, Pepperl+Fuchs (Factory Automation)

Raj Singh RatheeManaging DirectorKuka Robotics India

Jasbir SinghVice President – Electrical & InstrumentEssar Project Management Consultants

Dr KLS SharmaAdvisor Automation Education & Training

Mandar PhadkeCEO, Abhisam SoftwareFormer Head – Process ControlLanxess India Pvt Ltd

Arcot RajabahadurAutomation Consultant

Thampy MathewChairman, Fieldbus Foundation IndiaRegional Sales Director, Pepperl+Fuchs (Process Automation)

overseas Partner:

China, taiwan, Hong Kong & South-east asia

CO N T E N T S

Solutions for plant & machine safety

Market Management

32 “We strongly believe in local

management”

Interview with Oliver Vietze, CEO & Chairman, Baumer Group

34 “We help customers change the Way

they operate”

Interview with Jason Usro, Vice President & Chief Technology Officer, Honeywell Process Solution International

Chemical & Process 42 pervasive sensing

The article highlights the advanced measures used to make a plant modern, safe and environment-friendly

48 DoWntime For saFe Future operations

The article briefs on planned factory shutdown by INEOS for cleaning, maintenance and inspection

Focus

08 neWs

14 “ innovations are coming From smes”

Interview with Tom Kindermans, Vice President - Asia Field Operations, ANSYS Inc

16 “Focus is on nurturing innovation”

Interview with Victor Mieres, Vice President - Emerging Markets, National Instruments

18 “neeD to Develop evolving solutions”

Interview with Todd Graves, Vice President - Engineering & Technology, Allegion India

20 marKet trenDs

Focussing on optimising assetsA feature on adopting contemporary business practices through ALM models

36 rounD-table

Revamping automation education & trainingThe article proposes the various measures taken for making the young talent industry ready

CONTENTS

Solutions for plant & machine safety

Cover Story24 better process to proDuct

management

The article talks on technology changes for upgrading new automation systems

52 saFety & integration

The languages of automationThe article focuses on user-friendly techniques for automation tasks that vary from stand-alone applications to the implementation of classic automation

56 control & regulation

Designing via a new technologyAn article on adopting new motion control technologies for better performance

62 energy management

Taking eco-conscious decisions intelligentlyThe article focuses on Energy Intelligent Software for achieving sustainability

Technology

New Products

77 Automation solution for packaging; Energy measurement device; Terminal blocks to fight vibration; Safety light curtains

78 Engineering software tool; Test and evaluation kit for real-time Ethernet; Pneumatic rotary lift; Stripable control cable series

79 Light-weight laser profile scanner; Measuring light grid; Managed switches for Ethernet network

Columns

05 Editorial06 Contents80 Highlights - Next issue80 Company index

64 sensors & encoDers

Building designer expertiseA read into the latest sensor technologies that brings a revolution in the industrial system designs

68 event previeW

Platform for automated processesA pre-event report on Automatica 2014

event report

70 Convention of global innovationsA post event report on the recently held Hannover Messe 2014

74 Building an idea factoryA post event report on “Leveraging technology for quantum jump in business” by AIA

76 tech-talK

Rough & tough cablesThe article discusses the latest cable solutions used by the Indian tyre manufacturers

Advt

Cover image courtesy: SHUTTERSTOCK

Advt

marke t | news

8 a&D I nd i a | A p r-Ma y 2014

Enhancing deployment flexibility

Siemens PLm’s NX™ Software is now available in a cost-effective private

cloud environment. The company has worked closely with NVIDIA

Corporation to certify the

deployment of NX in the

private cloud using virtual

desktop infrastructure

(VDI) with NVIDIA GRID

vGPU (virtual graphics

processing unit) technology.

This technology enables

companies to use central servers with remote access and to host software

on a virtual desktop. It also optimises IT resources, enhances deployment

flexibility and further expands platform-of-choice option. “Virtual desktop

infrastructure” certification enables successful NX deployment in private

cloud. The new deployment option enhances flexibility and further expands

the wide variety of platform choices available to NX customers. As a result,

Siemens and NVIDIA are able to help one of their joint customers, Turkish

Aerospace Industries Inc. (TAI) successfully to deploy NX in a private cloud

environment. “By deploying Siemens’ NX in our private cloud using the

NVIDIA graphics environment, we can optimise resources and eliminate

strains on IT,” said Serdar Kaya, IT System Engineer, TAI.

HGS Automation ties up with Creaform

HGS automation has recently announced a strategic alliance with Creaform.

Under the agreement, HGS

Automation will sell, integrate and

commission fully integrated

Metrascan-R solutions, which

provide robot-mounted optical CMM

3D scanners for automated inspection

on and off the production line. Based

on the Metrascan 3D technology, the

R (robot) version offers high accuracy,

portability and an intuitive interface

to clients in need of 3D scanning devices for on-line measurements in the

automotive and aerospace industries. Incorporating this technology, this

solutions offer customers benefits like speed, fully configured and

programmed versatility, high accurate measurements up to 0.085 mm in

shop floor conditions, C-track’s dynamic referencing mode, automatic self-

calibration ensuring constant accuracy during the systems entire life cycle

and continuous parameter monitoring such as temperature and accuracy,

ensuring constant device accuracy during a systems entire life. The turnkey

solutions provide better quality, accuracy and repeatability. Moreover, they

reduce health and safety issues for repetitive tasks handled by humans.

The turnkey solutions provide better

quality, accuracy and repeatability

> MORE@CLICK ADI03430 | www.AandD24.in


Bringing advanced sensing technology to academic Institutions

Pepperl+Fuchs along with Ajay Kumar Garg Engineering College (AKGEC)

have recently established an advanced training set up for industrial sensing

at Center of Relevance and

Excellence, AKGEC Ghaziabad. It

is expected to aid the institution

in imparting education on

relevant technology and provide

a good platform to give hands

on training to students for a

deeper understanding of the

subject through real life

Industrial equipment. The

training set up and course

material are unique and tailored

to meet the growing needs of

Indian industry and engineering

education in the automation domain. It covers in-depth industrial scenarios

and has complementing hardware which suggests and trains the best-fit

technology and solutions. It aptly covers the domain of modern industrial

sensing, bus based technology, RFID and positioning systems. Students can

be trained in these areas on world class training kits too.


It is expected to aid the institution

in imparting education on relevant

technology

Schneider Electric partners with Ramco Systems

Schneider electric has partnered with Ramco Systems to offer advanced

process control optimisation solution for cement customers. The partnership

will see Ramco’s advanced

process optimisation software,

OPTIMA, become an important

part of Schneider Electric’s

solutions for the cement

industry and strategically help

explore business opportunities.

With cement manufacturers

focusing their efforts on

reducing energy and emissions,

improving overall performance

and managing consistent

product quality grade, plant

operators are looking for solutions that stabilise the production process

and maintain optimal operation point for minimal effect on the environment.

It also expects to focus on optimisation of kiln and mill operations to its

cement customers. It will support increased production volumes, promote

ease & uptake of alternative fuels and support human operators for best

decisions to change operating conditions.

The partnership will see Ramco’s advanced

process optimisation software, OPTIMA,

become an important part of Schneider

Electric’s solutions for the cement industry


marke t | news

10 a&D I nd i a | A p r-Ma y 2014

Memex Automation partners in THINC

Okuma has recently announced the partnership of Memex Automation in

THINC. Memex, which specialises in networking

machine tools and administration computers

allows productivity and other statistics to

have the ability to be sent digitally anywhere

in the world. The solution enables

manufacturing execution system improving

profitability, reducing waste and ensuring

compliance with regulations. The RFID asset

management shows asset information in real

time and works hand-in-hand with OEE, Lean

and Six Sigma. The merlin machine

monitoring typically increases shop floor

efficiency by 10%. Also, direct numerical

control allows simultaneous upload and

download of multiple CNC controls. “We are

excited to announce our new partnership

with Memex Automation. Their expertise and dedication to help

manufacturers obtain the highest level of profitability possible through real

time productivity information tools, makes them a great addition to partners

in THINC.” says Jeff Estes, Director of Partners in THINC.

ABB substation to help reinforce Indian power grid

aBB has won an order worth around $18 million from Power Grid Corporation

of India Limited (PGCIL) to construct a 400 kV gas-insulated switchgear

(GIS) substation at Kolhapur, Maharashtra. It

helps strengthening inter regional grid

between the Western and Southern regions.

“This substation will boost power

transmission to the Southern region and

increase inter regional transfer capacity”

said Oleg Aleinikov, Head, Substations

business, ABB. Key product supplies include

400 kV GIS, shunt reactors, control and relay

panels based on IEC 61850 platform. The

latest generation GIS has a compact,

modular and eco-efficient design, enabling

reduction in product volume, footprint and

weight, while enhancing eco-efficiency. The project is scheduled for

completion in 2016. ABB has previously supplied several GIS substations to

PGCIL and has recently commissioned the 765/400 kV substation at

Sholapur, ahead of schedule. The key node enabled the completion of the

Raichur-Sholapur transmission line, linking the Southern grid to the national

transmission grid.


The substation will boost

power transmission to

the Southern region and

increase inter regional

transfer capacity

The solution enables

manufacturing execution

system improving profitability,

reducing waste and ensuring

compliance with regulations


Emerson appoints Neoteric Infomatique as national distributor

emerson Network Power has recently announced that it has appointed

Neoteric Infomatique as a national distributor for small and medium

uninterruptible power

supply (UPS) products in

India. The company plans

to address the growing

demand from enterprises

for innovative and

technologically superior

back-up power solutions

devised for modern day IT

requirements. “IT resellers in India will now have access to Emerson’s

reliable and highly effective UPS solutions which can thrive in India’s power

infrastructure,” said Sanjay Zadoo, Country Manager - Channel Business,

Emerson Network Power, India. Emerson’s small and medium UPS product

portfolio includes the online and line-interactive product range. “The

company’s back-up power solutions enable enterprises to have reliable

back-up power and thereby, protect their IT infrastructure. We will focus on

on-boarding and enabling partners to provide Emerson’s state-of-the-art

UPS solutions that facilitate real-time infrastructure optimisation,” said

Rakesh Kaul, National Head-Sales, Neoteric Infomatique Ltd.


MATLAB EXPO 2014 in Bengaluru and Pune

mathWorks' matLaB eXPO 2014 will be hosted on July 10, 2014 in

Bangaluru and July 15, 2014 in Pune. It will bring together engineers,

scientists and partners to exchange ideas

and explore the latest product capabilities

in MATLAB and Simulink. The EXPO will

feature presentations by the company’s

technical experts and customers in India

along with an exclusive exhibition area

showcasing cutting-edge demonstrations.

Jason Ghidella, Technical Marketing

Manager, MathWorks, will present the

keynote address entitled ‘Directions in

Technical Computing and Model-Based

Design.” He will also discuss how MATLAB

and Simulink are equipping engineers and

scientists to respond to challenges and

opportunities arising out of mega technology

trends such as Big Data, cloud and mobile

computing, internet of things, low-cost

programmable micro-processors, online

education and more.

Jason Ghidella, Technical

Marketing Manager,

MathWorks, will present the

keynote address entitled

‘Directions in Technical

Computing and Model-Based

Design


marke t | news

12 a&D I nd i a | A p r-Ma y 2014

Kollmorgen partners with Ruju Corporation

kollmorgen has expanded its presence in India. The motion control

specialists completed a distributor

agreement with Ruju Corporation at the

recent SPS/IPC/Drives Expo in Nuremberg.

"The partnership with Ruju is an important

building block to enable our continued

growth in a strong market," said Udo

Panenka, Managing Director, Kollmorgen

Europe. “Kollmorgen’s high level of

expertise in servo drive technology and

motion control solutions immediately

provides us with real benefits as a

premier supplier of automation

equipment in our country," added Hiren

Joshi, owner & CEO, Ruju. "Based on our open and standardised product

platform, and together with Ruju, we can develop well scaled motion and

machine control applications for machine builders in India that are

accurately tailored and implement faster," concluded Alexander Hack,

Market Development Manager, Kollmorgen. These also include increased

opportunities to effectively address the rising energy costs in India with

efficient solutions.

Launching SPS Automation India

Messe Frankfurt India Trade Fair confirmed its partnership with

Pepperl+Fuchs to launch the edition of SPS Automation India. “P+F is glad

to partner with SPS Automation India for its debut show and looks forward

to displaying the existing

range of products and

technology trends in the field

of sensing and measurement,”

said Ravi Agarwal, Director,

Pepperl+Fuchs. SPS

Automation India, will take

place on February 5-7, 2015 at

Mahatma Mandir Convention

and Exhibition Centre,

Gandhinagar, Gujarat which

will be an ideal platform for this development while opening new avenues

and business prospects for the participating companies. It will display a

vast range of products & systems and also host a parallel seminar. “The

alliance has strengthened our resolve to provide an international standard

business & networking platform for the sector’s players, while focusing on

modern automation solutions for the Indian market”, said Raj Manek,

Managing Director, Messe Frankfurt India.


Lapp Group offers solutions for more efficient & flexible factory

Lapp Group has taken part in a number of research projects to offer

solutions for more efficient & flexible factory. The research mainly focuses

on the following questions: how could

the work environment look in a factory

of the future? What kind of tasks will

factory workers undertake and how can

they be supported in fulfilling their

tasks? “This is important for

understanding the entire production

system, that is the plants and operators.

We want to use our findings to develop

solutions that are even more suitable for

the factory of the future,“ explains

Siegbert Lapp, Member of the Board,

Lapp Holding AG. In addition to this, the

company is involved in the

SmartFactoryKL initiative run by the German Research Center for Artificial

Intelligence (DFKI). The SmartFactoryKL is a demonstration factory inside a

laboratory, where researchers from the DFKI can use technologies for the

intelligent factory of tomorrow in a production environment as close as

possible to the real world.


The motion control specialists

completed a distributor

agreement with Ruju

Corporation

Siegbert Lapp, Member of the

Board, Lapp Holding AG briefs

on the research projects

taken by Lapp Group

SPS Automation India -Driving confirmed

their partnership with Pepperl+Fuchs to

launch the edition of SPS Automation India


ANSYS congratulated two teams

competing in the BAJA SAEIndia

ANSYS honours engineering simulation teams

ANSYS has recently honoured two teams competing in the BAJA SAEIndia

all-terrain vehicle (ATV) development

contest organised by the Society of

Automotive Engineers (SAE) and

presented an engineering simulation

award. Team Nemesis from the College

of Engineering at Pune University and

Vellore Institute of Technology’s Team

Kshatriya successfully leveraged

ANSYS simulation for their individual

ATV designs. They used ANSYS

Mechanical™ to analyse its vehicle’s suspension components, chassis,

gearbox casing and brake pedal to reduce the weight of its ATV while

ensuring maximum strength. “ANSYS instituted the Engineering Simulation

award in 2010 to recognise student competition teams and organisations

who take advantage of simulation to optimise their designs, whether it’s

an ATV or formula-type race car,” said Murali Kardiramangalam, Academic

Program Director, ANSYS. “These contests are crucial to facilitate learning

simulation outside the classroom and by providing software, training and

support to these teams, the company is helping to nurture the next

generation of innovative engineers,” he added.


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a&D I nd i a | A p r-Ma y 201414

“Thoughtful engineers are the need of the future”

Tom Kindermans, Vice President – Asia Field Operations, ANSYS Inc, details on engineering simulation as one of the biggest initiatives taken to empower SMEs and discusses the various strategic

plans for the Indian market, during an interview with Srimoyee Lahiri.

What are your company’s strategic plans for expanding the Indian market share? We are worldwide leaders in engineering simulation and the market is growing globally as companies look to us for simulation expertise, and the competitive advantage we bring to their business. Overall, we want to meet market needs by investing in product development, adding more partners and improving infrastructure by optimising our team & operations.

From which sectors are you witnessing major demand?Major demand is witnessed from aerospace & defence, automotive, oil & gas and electronics

- the proportion of which however, varies by regions. We have worldclass expertise in each of these industries and are already adding a lot of value to several OEMs and suppliers.

What are the new age applications that are being launched in 2014-15?Indian organisations today are facing complex (and sometimes competing) pressures like never before. There is a need to create the next ‘must-have’ products which are affordable, first time right and yet priced such that organisations make profit. Hence, multiphysics analysis becomes imperative while creating such products and we are witnessing customers adopting it rapidly across the globe. The company’s innovative multiphysics software offers a comprehensive and integrated structural, thermal, fluid and electromagnetic analysis under a single framework.

What are the company’s expansion/investment plans in 2014-15?Automotive is in fact a very important area of potential for ANSYS in India and we have several ongoing initiatives with our existing auto customers. Aerospace & defence and oil & gas are two other important verticals for our India business. We are also connected with academia in several ways by supporting student competitions, sponsoring academic projects by funding and helping out professors.

How does R&D work in your domain? How is ANSYS focused on empowering SMEs?Our R&D is driven by customer requirements and the availability of the latest technologies. We spend about 17% of our global revenue on R&D. Education and awareness about engineering simulation is one of the biggest ways to empower SMEs. We have observed that more innovation is happening at the SME level in India than a decade ago, and innovation is gradually moving to SMEs as they mature.

Which technology trends have been witnessed in 2013? What are the expectations for 2014-15? In 2013, we saw SMB companies eager to learn more about engineering simulation and understand its value for their businesses. In 2014-15, we hope to see better investment climate that incentivises product development and innovation.

What are the challenges that are being witnessed in your domain?We are reaching a stage where every engineer needs to have an understanding of product development processes and engineering simulation. For a vast and diverse country like India there are challenges related to education policy, curriculum control

and industry-academia connect. A lot is being done by the government and private institutions but our focus on engineering research still needs a boost. ANSYS is trying to contribute by providing software and sponsoring research projects. Well trained & thoughtful engineers are the need of the future.

How do you align your market strategy with fluctuating demand scenarios? The fundamental strategy does not change dramatically. But of course, we do make adjustments depending on the current market scenario. ☐


16



“Focus is on nurturing innovation”Discussing the emerging technology trends in industrial automation, Victor Mieres, Vice President

- Emerging Markets, National Instruments, briefs on graphical system design for better functionality, during an interview with Srimoyee Lahiri

Globally, what is the strategic importance of emerging markets for NI? From a global standpoint, emerging markets possess key elements that make it strategically important. We expect to see continual strong growth from the emerging markets as we focus on mining, semiconductor and manufacturing to deliver productivity to our customers and foray into new markets with our tools and technology.

Your company is largely identified with LabVIEW. What are the emerging technology trends in the industrial automation domain? Through control design tools in LabVIEW, we can bring different models of computation such as simulation models, textual math and data-flow, thereby integrating it into hardware. Another interesting trend is the rise of cyberphysical systems. Most complex systems bridge the fields of computation, information technology and physics. An emerging field of science is the study and development of engineered systems that bridge cyber and physical worlds. They are engineered to continuously interact with their environment through the coupling of distributed computational and physical components. CPS applications are all around us and include smart grid, vehicle traffic networks, smart buildings, cooperative robots, telecommunications, automotive systems and avionics.

Which steps can be taken to encourage innovation in the engineering domain?

“Graphical system design” equips domain experts with hardware and software that is off-the-shelf and can be used to build complex engineering solutions easily because of the level of abstraction and flexibility that it provides to domain experts. This approach solves the challenge to learn multiple skills and tools to implement a system. The program focuses on nurturing local innovation through partnerships and supporting small & medium enterprises (SMEs), entrepreneurs and organisations building solutions that can contribute locally to the prosperity and sustainable development of emerging nations. Our academic program has initiatives such as collaborative research, LabVIEW academy and setting up centres for excellence that

enable such industry institute collaboration in improving the teaching-learning process.

Do you think the Indian mindset is open to experimenting with the latest hi-tech automation with better and more functionality? What are your views on the same?The graphical system design approach with its highly modular hardware and flexible software provide an ideal platform for Indian engineers as they design and build cyber-physical systems. Another area for growth is the big analog data, which is probably the oldest, fastest and biggest in the category of big data. It harbours great scientific, engineering and business insight. To tap this vast resource, developers are turning to

solutions powered by tools and platforms that integrate well with each other through a wide range of other vendors. This area is growing in demand as it solves problems in key application areas such as scientific research, product testing & machine conditioning and asst monitoring.

What are your strategic plans for NI for 2014-2015?In R&D innovation, we are redoubling our efforts to improve product offerings, especially for RF/wireless test applications and reconfigurable I/O portfolio using NI LabVIEW and FPGA technologies for test

and control applications. We aim to increase NI technology adoption, by working

with our stakeholders to create an ecosystem that combines hardware and software tightly integrated to create a standardised platform that can be shared across many applications to ensure customers’ success. On the business front, we will continue to invest in our regional infrastructure to guarantee technical and business support globally, extend our presence geographically in several cities in India as well as growing frontier markets in Africa and Asia. We are also collaborating with NGOs and international development agencies worldwide such as USAid and the World Bank to provide engineers and scientists with increased access to technology to achieve sustainable prosperity. ☐


18



‘Need to develop evolving solutions’ Todd Graves, Vice President, Engineering & Technology, Allegion India, during this discussion

with Sumedha Mahorey, addresses the safety and security requirements of the Indian manufacturing sector and its prospects in the coming years. Excerpts…

What are the highlights of the global safety and security market? In the manufacturing sector, as with other types of facilities, safety and security are dual requirements that demand a solution which balances the needs of both. Security is achieved when unauthorised people are kept out, while authorised people are allowed access quickly and easily, maintaining the productivity of the workforce. In a manufacturing facility, safety and security requirements are often paired with time & attendance, wherein workers “clock in” and “clock out” of their shift concurrent with gaining access to the facility.

Which are the evolving safety & security needs of the Indian manufacturing sector?Security is a mechanical problem on its most fundamental level. A physical barrier must keep unauthorised people out, while quickly and easily allowing authorised people in. However, as mechanical solutions have evolved with the addition of electronics, new levels of safety and security can be achieved. The addition of electronics further allows various safety and security systems to communicate with each other with a central control system and database. Communications and connectivity are enabling novel capabilities to be added, increasing the productivity of the facility to the levels that were not possible with purely mechanical solutions.

How is the Indian safety and security market likely to perform in 2014-15?As a growing economy and market, India will see its safety and security needs increase over the next couple of years.

What are the challenges and opportunities in the Indian market? With various markets across the world, Indian market is challenged with providing increased levels of safety and security for end users for the industry migrates to more connected solutions. Growing markets like India have a unique opportunity because new facilities do not have an existing infrastructure to migrate, so the designer of the facility is free

to specify the optimum solution from the beginning. The key is developing scalable solutions that can evolve as the customer’s needs change and the use of open protocols & standards makes this evolution much easier.

How is R&D and innovation strategy implemented at Allegion? We are committed to develop the most innovative safety and security solutions. We have invested in our R&D capabilities around the world, investing in people, tools and processes to get the innovations to market quickly. This is reflected not only in our long heritage of innovation, demonstrated by the fact

that Allegion invented many of the safety and security devices in common use today, but also in our investment in the India Engineering and Technology Centre. We have created a world-class facility to house a highly-talented engineering team, along with development tools and test equipment to allow them to turn their creativity into innovative new products and solutions.Allegion created the Disruptive Innovation Centre of Excellence (DICE) to tap into the creativity of our employees worldwide and turn their ideas into products quickly and effectively. DICE allows employees time apart from their normal responsibilities to work

on innovation, providing resources they need to collaborate freely. Our team in India is one of the most productive in terms of new innovations, reflected in large number of patent filings coming from our team here.

How will the new Bengaluru-based Engineering Centre help Allegion tap the Indian market potential? Allegion’s Engineering and Technology Centre in Bengaluru develops products for all of our markets around the world. It is one of our largest engineering centres, and it plays a key role in developing mechanical, electronic and software solutions that serve our global markets. The Indian team is highly skilled and creative, and is in the lead by developing some of our most important innovations, which improve safety and security around the world. ☐


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Focusing on optimising assetsThe article briefs on the traditional ALM practices on managing assets with a narrow vision on asset lifecycle that are becoming obsolete. As processes evolve there is an urgent requirement to shift gears and move from traditional to contemporary ways of doing business. ARC analysts have done an indepth research on this and designed an asset lifecycle management (ALM) model with a focus on improving and optimising assets throughout its lifecycle.

Companies in India today realise that improving asset performance is a key component for success in the competitive market. Major global players have established their presence across most industry verticals in India, raising the benchmark for domestic companies to scale up in terms of productivity, quality and time-to-market. In this market scenario, it has become mandatory for companies to focus on reducing operational cost to remain competitive. On the other hand, due to expanding regulatory requirements and increased concerns about security, companies need to allocate budgets on features and aspects that doesn’t necessarily improve the

bottomline. In addition, due to the present uncertain economic climate, companies are hesitant to invest more on creating new assets – and that adds further challenges of “doing more with less.” Hence, it is clear that better asset management is a pivotal business driver.

Improved management of assets and its optimisation requires clear understanding of the asset lifecycle. The traditional ALM practices on managing assets with a narrow vision on asset lifecycle are becoming obsolete; as processes evolve it is important to shift gears and move from traditional to contemporary ways of doing business. ARC analysts have

Piyush DewanganAnalyst - India & South East Asia ARC Advisory [email protected]

G GanapathiramanCountry ManagerARC Advisory Group, [email protected]

mArke t | tr end s

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t r e n d s | mArket

Focusing on optimising assets

done an indepth research on this issue and designed an asset lifecycle management (ALM) model with a focussing on improving and optimising assets throughout its lifecycle.

Traditional v/s new model for asset lifecycle management

Traditionally most companies think of ALM in terms of a linear model. While this captures the major ALM activities from creation to disposal of a complex asset, it also has major drawbacks for understanding ALM information management challenges. The model explains ALM as three major processes: project performance management (PPM), asset performance management (APM) and asset & project portfolio management (APPM), which some might simply call planning.

Capital assets: The traditional model represents a limited view of capital assets. Focus is solely on the physical plant while performance in real plants depends upon an extensive set of supporting resources. An appropriate view of a facility includes three classes of assets: physical, human, and virtual.

The ALM model focuses on the importance of all these assets when it comes to asset performance. Physical assets play an obvious role, since no facility produces anything without some equipment. But, the quantity, quality and value of that output can be directly influenced by the organisation’s human assets. Likewise, the performance of both equipment and humans depends upon having high-quality information. In the end, these are all vital pillars of asset performance and care must be taken to ensure that they are always synchronised and balanced.

Independent v/s interdependent: In the traditional model the major ALM processes and their relationships are represented as if they are sequential and independent activities.

The reality is that certain activities repeat many times as the facility is upgraded. This leads people to make poor decisions in critical areas like staffing, training, partnering, investing in technology and information management. The model represents the relation between the major ALM activities. The three major ALM activities are interdependent and overlapping and require information sharing and

collaboration. Linear v/s cyclic: The traditional model presents ALM

activities as one-shot efforts. This is acceptable if companies are only focused on projects, but is misleading for someone who manages assets over their complete lifecycle. Real assets get old and have upgrade and modification projects that cause the process to repeat. Hence, with traditional approach, the lack of information on key asset health often leads to challenges on upgrades and other improvement programs. The model understands this cyclic nature of activities and hence major activities are represented in a circular manner rather than linear. The circular representation indicates that it is an on-going activity which requires continuous improvements during the lifecycle of the plant. Hence, it is incumbent on the managers of each process to make sure that information and lessons learned in one project or plant are captured and made available for improvement on other projects and plants.

Management responsibilities: The traditional model recognises that design & build is responsible for sourcing material and building the facility. But the new model highlights the fact that their responsibility also includes the management of all information created or collected in the following stages

— making sure that spare parts are acquired in time for commissioning; that IT systems used to operate and maintain the facility are in place and initialised with all needed information; that procedures are available in time for operating and maintenance personnel to be trained before accepting the facility and others.

ALM strategies can succeed only with proper information management; hence AIM is of vital importance.

Information management – an important tool for the success of ALM strategies

An owner-operator’s capital assets is more than the physical equipment that one sees during plant visits. Human assets are needed as well to build, operate and maintain these facilities and they need require asset information to accomplish their tasks. Hence, information is an essential part of every asset investment. It forms the virtual asset that the ALM Team needs to understand and manage the physical and human assets at

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each facility. It must be complete, comprehensive, accurate and granular enough to support queries about the asset’s creation, use and its care throughout its lifecycle.

Asset information is good when it is trusted and used by people in their decision making across all of the ALM processes. To achieve these goals, its characteristics should comprise of complete - all information for every asset in every relevant category; accurate - with respect to the existing situation; consistent - across all documents and object instances; accessible - by authorised ALM stakeholders using reasonable knowledge, in a form that conveniently meets their needs and timely - reflects the current situation with reasonable measures of realtime.

From a content perspective, this means that an organisation needs access to reference data for every asset’s functional capabilities, its physical design and how humans are supposed to assemble, operate and maintain the equipment in a safe and efficient manner. All of this reference data needs to be carefully managed for change to ensure that virtual representations always match reality. Some people will also have questions about asset performance and the root cause of problems and incidents. So, the content must also include activity records reflecting current status and the decisions and actions that occurred during the facility’s design, procurement, installation, use and maintenance. And, to be effective, all of this information, reference data and activity records, need to be cross-referenced.

From a toolset perspective, these characteristics imply that the organisation has an asset information management technology strategy that supports diverse set of users, each with their own needs and preferred views of the virtual asset. This includes a general, yet powerful search capability that supports queries related to certain assets, issues, time periods, etc. Comparisons of information across different plants, different instances of a given kind of asset, different time

periods, etc would also be possible. Users would likewise be able to view information in various formats, from a variety of devices and through various applications that support their individual workflows.

Better asset performance

The value of better asset information management lies in its ability to improve asset performance, whether the asset is human or physical equipment. Better information about process parameters can improve a designer’s productivity and help them make better equipment selection decisions. The same information can help operators and automation systems optimise throughput and energy costs of a facility once it is operating. But these latter benefits will be lost if the information is not shared across asset lifecycle stages.

There are two channels through which better asset information management improves performance of human assets. Firstly, it can directly impact the productivity of an individual or, better yet, a whole group of individuals. Secondly, it can enable better collaboration between people and groups, which indirectly improves everyone’s performance. In both cases, these improvements contribute to asset performance through lower capital costs, shorter project schedules, lower operating costs, etc.

In a similar fashion, better asset information management can improve physical asset performance. It can be used to improve a facility’s functional performance in terms of throughput, yield, quality, and such others. It can also help in terms of increasing the facility’s availability for productive activity and extending equipment lifetimes. Finally, better asset information management can improve performance in critical areas like environmental, health and safety (EH&S). ☐

Asset lifecycle management:

Traditional vs ARC’s Model


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cov e r sto ry | t e ch n ol og y

A comprehensive approach towards automation

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A&D I nd i a | A p r-Ma y 2014

Better process-to-proDuct mAnAgement

Automation may not limit itself to process controls, advance control and optimisation in one unit or one plant but seamless integration with ERP systems, Management Information System (MIS) shall be part of automation. The article talks on these technology trends, considerations for adopting automation technologies, and end-user expectations from automation solution providers.

B R MehtaSenior Vice President Reliance Industries Ltd

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A comprehensive approach towards automation

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maintenance. With approximately 50% of the work accomplished in most organisations being reasonably preventable maintenance, potential cost & savings from utilising device diagnostics data are tremendous.

In the process control industry, instrument assets range from field devices to hardware/software based control solutions. In order to maximise the output of an industrial facility, all instrument assets need to be maintained at certain intervals — i.e. monitored, serviced, refurbished or replaced. Instrument asset management assists in determining these intervals through continual asset condition monitoring, which predicts time-to-service, detailed diagnostics with guidance of required service actions and system-supported planning and execution of service tasks. The goal of an instrument asset management solution is proactive rather than reactive maintenance, wherever possible.

High performance HMIs: Some benefits of better optimising on HMIs include better handling of abnormal situations and effective response, effective alarm and event management. Since humans recognise shapes and colours faster than numbers, use of Pattern Recognition Objects (PRO) will provide effective graphical overview of simultaneous process conditions. Shapes/colours will change to alert onset of abnormal condition for operator to take quick corrective actions. Also, superimpose pre-captured patterns with real-time patterns and real-time performance feedback & KPI for selected parameters will help.

Implementing automation systems

At times, different vendors are used for implementing the overall control system plan. This is done to harness the core competency of different solution providers. Open control system architecture plays a major role in tightly integrating the different modules of control system, and makes them work in unison.

It is never an easy task to fulfill all requirements of process control and safety. Seamless integration of DCS & ESD and integration of various systems with DCS like machine condition monitoring, compressor control systems, analyser management, fiscal and allocation metering systems, automatic tank gauging systems, PLCs for large mechanical packages is always a challenging task. To design & implement safety instrumented systems and mitigation layer system like fire & gas system is also very critical in nature.

Automation @ Reliance Industries

In a refinery, there are various process systems like advance

The manufacturing value chain is moving towards efficiency and low cost of manufacturing globally. In purview of the changing world order after globalisation, economies of scale are tilting in favour of nations where there is great demand. This paves the way for countries like India and China, to secure their manufacturing capacity to meet dual demand of meeting the domestic market and that of the international market with lower cost of manufacturing. Automation will certainly have a major role to play to attain the goals of low cost of production in meeting the scale and the scope. Optimising automation subsystems

Virtualisation: Nowadays, manufacturing automation systems are heading towards virtualisation of operator system interface (Level-3 applications), with running multiple operating system, on single physical machine by dividing system recourses between virtual machines; isolating fault and security at hardware level with advance recourse control preserve performance; migrating any virtual machine to any similar or different physical service, which gives hardware independence; and optimum utilisation of servers through recourse utilisation. Through virtualisation, high cost related to maintenance, network and disaster recovery plan can be reduced. It also helps in creating centralised system management.

Asset management: From an instrumentation and control perspective, equipment such as instrument and control can be considered as instrument assets which need to be maintained and managed to derive the value for planned duration/life cycle of the equipment or instrument. The equipment such as instrument needs to be maintained for proper operation due to its contribution/criticality while deriving the value to the production as a whole.

As the ability to self-diagnose device health and integrity improves, available information is too valuable to ignore. For example, standard temperature measurement options offering hot backup redundancy are being expanded into detecting sensor drift and predicting when a temperature sensor will fail.

Pressure transmitters now detect plugged impulse lines and inform the operator when an apparently good measurement is, in fact, not valid. Control valve diagnostics and the ability to execute partial valve stroke test or generate valve signatures for online diagnostics allow many valve problems to be easily isolated and remedied without the cost associated with pulling a valve out of service and unnecessarily rebuilding it.

All of these developments in device diagnostics help processing facilities practice more preventive and less reactive

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process control, tank farm management system, ESD system, F&G system, oil movement system and blending & optimisation system, terminal automation system, among others, all working in tandem and in perfect synchronisation.

The mission of automation in Reliance Refinery was to achieve operational excellence in monitoring, controlling & managing process and business; optimum level of integration between process control, operation & business support systems; and showcasing corporate image of Reliance Industries providing next generation control systems.

The objectives achieved by us with the implementation of Foundation Fieldbus technology and new smart devices include inter-operatable products & systems; elimination of proprietary protocols; technology enabling innovation by manufacturers; device diagnostics; lower installation costs; more information from the valves; multiple inputs from one device; new instrumentation easier to add later; reduced wiring; reduced terminations; reduced commissioning time and reduced control room space.

Process control systems were traditionally closed systems designed for functionality, safety and reliability where the prime concern was one of physical security. Increased connectivity via standard IT technologies has exposed them to new threats which they are ill-equipped to deal with (for example, worms, viruses and hackers). As this process control networks continue to increase in numbers, expand and connect so the risks to the process control systems from electronic threats continue to escalate.

Commercial off-the-shelf software and general purpose hardware is thus being used to replace propriety process control systems. Such software and hardware often does not match the uniqueness, complexities, real-time and safety requirements of the process control environment. Many of the standard IT security protection measures normally used with these technologies have not been adopted into the process control environment. Consequently, there may be insufficient security measures available to protect control systems and keep the environment secure. Additionally, software and hardware applications are difficult to upgrade in a control system network. This acts as one of the challenges industry is facing. Also, securing control systems may not be perceived as

economically justifiable. Industry is facing security challenges from internal as well

as external world. The internal threats include disgruntled employee, viruses and worms, accidental system changes and malicious users. While external threats include cyber hackers, viruses and worms, spyware (trojans), and terrorist attacks.

Ideally, integrated security solutions for preventing illegal entrance, viruses and cyber-attacks or financial loss must be infallible. Although no single technology can claim to be completely flawless, layering multiple security technologies can leverage the capabilities of each technology, overcoming the limitations of any single technology. Moreover, threats to system vary in nature, so different technologies provide different solutions for different type of threats.

Expectations from automation solution providers

End-user expectations for reliability and speed have grown dramatically as more and more users have come in contact with wider arrays of software applications. End user inputs to vendor are precious because it brings future into the present and avoid becoming insular.

As end users, we expect, life cycle excellence from the concept to optimisation; single integration architecture; enterprise integration; cyber security protection; application integration; productivity & profitability through technology and services; shortening delivery times & reducing time of start-up; reducing the “four Cs” – cost, commissioning, customisation & coordination; smart service capabilities; value-added services for maximisation in profit; least cost of ownership of the control systems; Mean-Time-To-Repair (MTTR) to be minimum which can be achieved by service centre at site. Apart from this, the application developer tool should be user-friendly and easily upgradable without calling for a process shutdown. The application programs should be easily scalable to meet any capacity growth.

Considerations for new technology deployment

Normally, while selecting the new technology like Foundation Fieldbus, we consider three major aspects – the

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Diagnostics based on NAMUR 107 standard can provide pin pointed data to operation and maintenance person on health of instruments

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future of process automation, proven technology and openness. We consider benefits which come during the life cycle of the project which is typically engineering, construction, commissioning & start-up, operation & maintenance. We ensure that the infrastructure is neutral; standard based, provides end-users with a common framework to implement and manage the strategies & are continuously improving. We also learned that it is non-proprietary, open, interoperable & continuously evolving with vendors coming in with various innovations.

Drivers for industrial automation

There are five major identified driving forces most likely to impact on industrial automation businesses. These forces are the transition from – transactional to real-time business environment; process to product management; labour workers to performance managers; an island to a holistic business perspective; and from rigid to agile operations.

Any automation manufacturer has to come-up with innovation, latest technology, and cost-effective solutions to remain leader in the market. Also, in place of standard offerings they should offer value-added solutions/offerings to end-user.

Many of the manufacturers today compromise on environmental and health aspects and thereby, harm the community at large. They use obsolete technology to produce the product with the just acceptable quality but not meeting the other standards of production which calls for efficiency and lesser environmental impact. To subjugate this problem, various manufacturing forums as well as government statutory bodies should effectively help legislate and implement laws that would address not only product quality issues but also production quality issues without jeopardising the profits.

This will trigger new wave of automation within the automation sector. Manufactures should work as a stakeholder of the society rather than working in their silos. Advanced automation technologies can certainly add more value in this process of reform in the industry within India.

Involvement of the expert team from projects, operation and maintenance from the early days of projects and effective interaction with selected vendors and other end-users has made the automation technology of refinery ‘future proof ’. We have immensely benefited after implementation of Foundation Fieldbus technology. This has enabled us to prioritise various process and system alarms as per the latest automation standard and trends in the process industry.

Device monitoring and information during the service fault and other diagnostic information has helped in predictive maintenance. Real-time Plant Asset Management (PAM) has given us access to plant health field devices and automation system; and ability to add new devices with reduced time, wiring and termination. Technology has built-in standard safety functions such as device failure, function check and maintenance request with single operator display. Since display is digital, it eliminates conversion such as analog to digital which has improved accuracy and reliability. We can integrate certified products from different suppliers to selected system uniformly with standard features which will allow for interchangeability. More IT tools are integrated with process automation software with high level of system security and integrity that will help process, automation end-user in many ways.

New age technology developments

The bottleneck in technology advancement shuttles between hardware and software periodically and is being continuously addressed by the automation world. A radical change coming from the fundamental research in physics can bring in a disruptive change in the automation world, just as it came after the advent of semiconductor technology.

The future of automation will go hand-in-hand with the IT industry. Automation industry has been evolving very fast with the advent of microprocessor technology that offered flexibility of implementing our process control strategy. There have always been spillovers from consumer technology within

Many unnecessary checks can be avoided which is about 63% of the time spent on investigation

of problems which do not exist

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the automation world. For example, advancement in IT and telecommunication technology has widely influenced the automation industry. There is a definite shift from the age old proprietary hardware and software systems towards more open universal hardware and software systems, which offers better interchangeability of automation products. The differentiation points are the application layer and the hardware at the I/O level, with better availability and Mean-Time-Between-Failures (MTBF) figures.

Another concept getting popular in process automation is Remote Operation Management (ROM). Due to rising operating cost, the plant operations are becoming more geographically dispersed. The traditional approach now do not work with dynamically changing supply and demand; tighter production specification and environmental norms; challenge in identify skilled and qualified human recourses. In order to counter-act such difficulties in present scenario, concept of ROM comes as solution.

ROM can be used by conventional method of collecting data from systems and analyse the data as per the end-user requirement.

Another ROM concept which is not popular in process industry, but used for the smaller size automation application, is cloud-based ROM. In cloud-based ROM, the data is collected and stored in remote server through various communication gateways such as serial communication, Modbus RTU, or GPS; this stored data is accessed through secured network such as Ethernet IP, GSM or GPRS for end-user through customised online display.

Recent development on ROM concept is being thought of by integrating wired infrastructure, remote I/Os and ISA wireless infrastructure, into FF infrastructure data management. This will enable real time operation management through more effective use of various data structure, data quality, in turn increase reliability and availability with predictive maintenance strategy. Control has already shifted to field with the maturing of the Fieldbus technology.

Recent developments in wireless technology have offered

flexibility in monitoring points; less capital and operational cost; freedom from cables, JBs, isolators, marshaling cabinets and DCS I/Os; reduction in commissioning and engineering efforts; employed for monitoring of steam traps, relief valve leakage; vibration applications for cooling tower motors, fin fan coolers, rotary valves and non-critical pumps to support predictive maintenance. Other benefits include non-critical parameters monitoring and ease of addition of new devices with minimum engineering efforts. Wireless technology will also facilitate to achieve sustainability, monitoring health of steam traps; detecting safety valve passing or leaking; flare gas recovery unit load monitoring; managing effluent treatment plant (ETP) for better environment.

Future trends in automation technologies

In the future, mega scale manufacturing plants/complexes are expected to take advantage of scales of production at single location. To maximise operational efficiencies and yield & to achieve faster ROI, mega plants shall have to be equipped with maximised automation. Automation may not limit itself to process controls, advance control and optimisation in one unit or one plant but seamless integration with ERP systems, MIS shall be part of future automation. Nanotechnology may be used in developing tiny, low power, highly accurate sensors which will showcase direct impact on low cost of production in the future. Cloud computing may also be used to optimise costs.

Automation shall have a maximum impact in future projects in terms of scope, cost, schedule and manpower. A comprehensive and integrated approach towards safety is essential to achieve higher level of plant safety. And such an approach must include securing the process control network, responding quickly and accurately to abnormal situations, early detection of defects, proactively monitoring asset health, moving the plant assets into safe state and managing emergency situation quickly and efficiently. ☐

High performance HMI helps in detecting

abnormal situation before alarm occurs

Delta has applied its knowledge and technology in automatic control and electric power to expand its automation products,

systems, and solutions for application in a broad range of industries including packaging, textiles, chemicals, electronics,

printing, and pharmaceuticals.

As a leading industrial automation brand, and as a reliable partner to worldwide customers, we provide efficient and

reliable solutions in factory automation, process automation, and machine automation for many major companies.

For details and enquiries please mail us at [email protected]

www.deltaelectronicsindia.com

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“We strongly believe in local management”

...says Dr Oliver Vietze, CEO & Chairman, Baumer Group, in an exclusive interview with Shekhar Jitkar and Srimoyee Lahiri. Briefing on the acquisition of Waaree Instruments in India and sharing insights on implementation of Six Sigma/Lean techniques, not only in production but also in all aspects of business, Dr Vietze elaborates on how average customer have become more techno-savvy and demand more intelligent sensors.

What are your strategic plans for India in terms of market positioning, expansions, manufacturing activities and tie-ups, if any?Baumer started its active direct presence in India through its wholly owned subsidiary in 2007 set up at Pune under the name Baumer India Private Limited. The company has established itself in the last five years and has significant market leadership in certain segments of factory automation market. The acquisition of the Waaree Instruments, three years ago has boosted our activities in the Indian subcontinent with manufacturing set up. It complements the international expansion strategy of the company. It is also an excellent opportunity to strengthen our process instruments business.

The Indian operations have improved our ability to meet local customer requirements, speed up local delivery and to react timely to the dynamic and growing Indian market. Our manufacturing locations are spread across Western Europe including two in Switzerland, six in Germany, one location each in Denmark, Venezuela, France.

We globally cover five segments including sensor solutions, motion control, process instrumentation, vision technology and gluing systems, finding applications in diverse range of industry segments such as print graphics, packaging, pharmaceutical machinery, food/beverage wind energy, cranes, steel, metal and material handling, among others.

Our expansion plans are based on making the best use

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efficiency (using ‘Six Sigma’) have become the key aspects of success.

Would you like to comment on the acquisition of Waaree Instruments in India? How is it running, so far? Baumer acquired Waaree Instruments three years ago. This was purely Indian company and within the last three years we have done lot of fundamental work on the organisation. We have worked on people and technology front. This is to bring new Baumer Technologies India at par with international Baumer quality.

With constant pervasive changes in technology & market requirements, how can organisations design/plan the change management process and product development strategies? Would you like to give any examples from Baumer?Baumer runs continuous program to improve organisation, processes and people competence. The company makes extensive use of Six Sigma/Lean techniques not only in production but also in all aspects of business. Baumer Business Systems (BBS) is a global program wherein all Baumer companies worldwide participate to exchange know-how and experience to ensure value addition at each stage of organisational activity. Moreover, as an open culture company, we facilitate know-how transfer at multiple levels and are not restricted to top driven actions.

What kind of innovations/technology breakthrough is expected from your company in the coming years? We are one of the leading companies in sensors and sensing technologies. We want to maintain the focus on sensor development. Sensor technology is a growing field in automation in every industry vertical. We feel the trend towards use of sensors in each product and commodity will continue. With average customer becoming more techno-savvy, there is more and more demand for intelligent sensors. ☐

of the available local talent. We strongly believe in local management. Indian unit is integral part of our global strategy to build products catering to high technology requirements at sustainable price.

Where do you see your Indian operations leading to in the next five years among Baumer’s global network?The integration of the Indian market is essential part of the international growth strategy of Baumer. The sheer size of the Indian market makes it imperative that no global strategy can be worked out ignoring India. We see India contributing significantly to our global business.

How do you look at the trends in the sensor business, technology & market? Where do you see the potential coming from, geography & sector?Sensor business is driven toward offering many high performance features within standard products. Utmost product reliability and safety features integrated into products and component sale coupled with application know-how and consultation are some of the trends. Manufacturing efficiency becomes more important under trying economic environment. Globally, major growth will come from the emerging markets in Asia, Africa and South America.

There has been an increasing trend in the sensor business which points at miniaturisation, precision, safety & measuring speed. How does Baumer take care of these demand expectations?These may have become the latest buzzwords, but for Baumer we have been offering these features on customised basis working closely with our OEM customers from Switzerland and Germany for last several decades. Technologically speaking this is not new for Baumer. The change however is that some of these special features have to be incorporated in the new product ranges we offer for the general market. That is where innovation in product design and emphasis on manufacturing

“The sheer size of the Indian market makes it imperative that no global strategy can be worked out ignoring India. We see India contributing significantly to our global business” Dr Oliver Vietze


man age me n t | i n t e rv i e w


“We help customers change the way they operate”Elaborating on cyber security, Jason Usro, Chief Technology Officer, Honeywell Process Solutions & Vice President and Chief Technology Officer at Honeywell International, highlights the recent technology advancements for a better control system and the recently designed solutions to enhance process safety & security, during an interview with Srimoyee Lahiri.

Honeywell has several new technologies that are likely to transform control rooms of the future, including an advanced dashboard to help industrial plants better manage control system cyber security. Please elaborate.Today, plants need to be highly automated. Hence, we have introduced several new technologies that will transform control rooms of the future in the way they implement, operate and maintain their control & safety systems. These technologies have been designed to make operators more effective in their daily tasks and decision-making. Technologies like OneWireless extends control room to the field, where industrial handheld devices that are linked together through wireless technology can free control room operators from their consoles and allow them to be more productive and autonomous; or cyber security

management systems like the Cyber Security Dashboard that focuses on removing risk from the control system environment. It can be customised to help industrial plants better manage control-system cyber security; and collaboration solutions like Experion Collaboration Station that enables faster responses to both routine and emergency situations by displaying a common view of how distributed assets at multiple locations are functioning.

In which areas of automation technology do you expect to see significant levels of automation in the coming years?Honeywell Experion Orion console is a futuristic console that reduces operator fatigue with an improved, ergonomic design featuring a larger display and alarm lighting. We

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i n terv i e w | management

Control System (DCS) architecture, including field instruments, SCADA, plant historians and other advanced control functions such as simulation software and advanced process control and optimisation applications.

How are you planning to drive the growth of your company in India? What are your strategies to enhance the market share in India.We are well-positioned to grow our business in India, and help drive the growth of the Indian economy with innovative technologies. We will continue to expand our footprint in Asia Pacific. We work with our customers, listen to them, understand their challenges and then come up with solutions. This means we help customers change the way they operate making them more flexible and productive. It also means that we change how they make decisions, the speed of those decisions, and even the place that the people need to be when making those decisions. Our objective is to engage with the customers beyond supplying just products and simple point solutions, and become a trusted advisor in helping them achieve their critical business goals.

We understand the demands of our customers and hence have a strong commitment toward developing and delivering solutions that are relevant and competitive for the local market. For example, PlantCruise by Experion, a proven DCS helps maximise users’ production uptime, improves safety, reliability & efficiency and reduces investments and operating costs. It is a product that is designed and developed based on customer inputs from the region; or SmartLine transmitters that is designed to enhance communication abilities, improve operational efficiency and reduce lifecycle costs for process manufacturers. ☐

have also introduced Collaboration Station that allows industrial organisations to monitor and manage operational activities across multiple facilities from anywhere within a network of sites, helping plants better leverage their expertise between locations, mitigate staffing issues associated with remote locations and maximise production and optimise operations. Core process industries such as oil & gas, refining, petrochemicals, power and chemicals can significantly benefit from advanced automation technologies too.

In the current uncertain economic situation, what would you advise to manufacturers for investment in automation technologies?Our technology is oriented toward helping customers become more profitable. In terms of advance control and optimisation, we can reduce customers’ energy costs or improve throughput without requiring additional capital being invested. On the other hand, technologies like alarm management helps to provide information to the operators so they can better address process problems before reducing production and finally shutting down the plant. Currently, what are the innovation themes that your company is working on?We develop cutting-edge technologies that address global macro trends such as safety, security and energy efficiency across different industries therefore helping customers. For safety & security within plants, we have designed solutions that enhance process safety & security and allow customers to operate in a safe manner while reducing the number of incidents that occur within plants. We are also innovating on energy efficiency. To ensure maximum optimisation benefits, we integrate advanced energy solutions with the customer’s existing Distributed

“Our objective is to engage with the customers beyond supplying just products and simple point solutions and become a trusted advisor to help them achieve their critical business goals” Jason Usro


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man age me n t | roun d -tabl e

a&D I nd i a | a p r-Ma y 2014

Revamping automation education & trainingWith the automation industry becoming the backbone in major manufacturing verticals, Indian institutes and colleges have been gearing up and updating their syllabus to suffice the demands of the industry. This feature analyses the challenges on this front, and the various measures being taken to make young talent industry-ready.

The Indian automation industry is the backbone of the manufacturing sector which has been a major contributor to the growth of Indian GDP. But this industry has been facing a serious dearth of young talent, despite the country producing lakhs of young engineering graduates every year. This feature provides insights into the human resource & talent acquisition challenges in the automation industry. Suggesting feasible solutions for the automation industry and the academia for young talent development are industry stalwarts Anup Wadhwa, Director, Automation Industry Association (AIA); Dr KLS Sharma, Advisor, Automation Education and Training; S S Prabhu, Professor (Emeritus), Advisor, IIITB; Renukaprasad Belgur, Business Mentor & Advisor, MentorWise Advisors, President of ISA (Bangalore Section) and Former Executive Director, Avasarala Technologies; Girish N Ayya, Consultant – Industrial Automation & Corporate Trainer and Co-Founder, Avadhoot Automation; and Sukumaran Mathoor, Senior Member – ISA & President Elect – ISA Bangalore Section and

General Manager – Operations, Pepperl+Fuchs (India), Process Automation Division.

Creating a right mix of theory, practice & training

There are many reasons for the gap between industry and academia even though industry and academia are continuously striving together to bridge the gap in areas such as education, training, research, development, etc. Highlighting these issues, Dr Sharma avers, “The industry keeps adopting latest and diverse technologies quickly to stay in business, but the academia faces difficulty in keeping pace with the industry. The syllabus update process in academia is very slow for procedural reasons; also, text and reference books on latest technologies are non-available in the market as the same remains with the industry, and its percolation into public domain is slow and restricted. Qualified, experienced, trained teachers and state-of-art laboratories to introduce the latest


Sumedha Mahorey Deputy Editor [email protected]

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round- tab l e | management

a& D I n d i a | a p r- M a y 2014

This is because of the enormous changes taking place in various technology areas, new technologies emerging, interdisciplinary nature of technologies, the presence of computing and communication technologies in almost all engineering systems, etc. The effort is to convey the broad sweep of modern engineering systems, give students a reasonable background in computing and communication, and enable them to study particular areas of interest through elective course concentrations. Increasingly, project work in small groups is encouraged. It is unrealistic to assume that engineering education will prepare graduates who are ‘industry ready’ for any particular industry. They will, however, have strong background and preparation to pick up engineering practice of relevance to their specialisations in a very short time.”

Providing suggestions on overcoming the many challenges education institutes are facing, Dr Sharma elaborates, “Certain steps can help bridge the gap between industry and academia and make engineers industry-ready. These include introduction of a new discipline with the name ‘Industrial Automation’ and making it open to all electrical science students at pre-final and final levels in under-graduate program; introducing a basic course addressing the philosophy, technology, terminology, and practices of modern automation to serve as a platform for all the subsequent courses in automation and domain related areas (supporting and advanced) and tailoring the subsequent domain supporting courses (Electronics, Communication, Information technology, etc) to address automation related issues, rather to keep them general in nature followed by advanced courses in automation.”

Structuring automation training for freshers

Despite education institutions taking the above measures, it is apparent that automation engineers who have already passed out and are deployed on-job should be provided the relevant knowledge & content on the continuously evolving

products, systems, and solutions are also not available.” The above leaves a gap between the fresher’s knowledge

level and industry’s expectation. This affects induction (recruitment, placement, deployment, and absorption) of fresh graduates into industry, as reasonable comfort level does not exist between the fresher and industry. “With this, many freshers perceive industry is not for them and many industries perceive freshers are not for them. This leaves freshers losing good employers and industry losing good freshers. This exists in all areas and automation industry is no exception,” he points out. Addressing these issues, Wadhwa suggests, “Active engagement with automation industry would help create curriculum relevant to a globalising country. A suggested mix for the institutions that want to produce globally competent automation engineers should have 40% classroom learning, 20% practical (automation labs), 20% digital self-learning through webinars and videos (class learning/individual learning), 20% exposure through internship/hands-on experience in manufacturing unit, guest lectures & discussions with professionals from automation industry and user industry. This will help students to connect with the real world of science and technology, develop critical and analytical thinking about processes and also nurture their entrepreneurial spirit and ideas for innovation.”

Adding on Wadhwa’s thoughts, Mathoor asserts, “Faculty Development Programs can be organised by academic institutions, in which experts from the automation industry can share their experience. This will help faculties from academic institutions to update their knowledge and skills, interact with the industry experts and revise their syllabus accordingly. Faculties from academia can attend special training courses offered by automation system manufacturers/other organisations like ISA, which will help meet this objective partially. Institutes can also look at hiring professionals from industry as consultants, who can support these activities. Conventional instrumentation laboratories in engineering colleges need to be upgraded by installing latest technology, automation products & systems as well as engineering tools & software used by industry.” Addressing the issue at hand, Ayya says, “Industry academia interactions on a regular basis by way of seminars, technical events, road shows, technical quiz, etc to connect the students to the industry will also help majorly.”

Giving his perspective on the challenges in automation education & training, Prabhu shares a practical viewpoint.

“Engineering education has been changing in the recent times.

“The human resource departments in automation sector industries can & must learn from IT organisations on how to attract young talent”Sukumaran Mathoor, President Elect - ISA Bangalore Section and GM – Operations, P+F Process Automation (India)

“With new technologies coming up in automation, we can keep the passion of an engineer alive” Anup Wadhwa, Director, Automation Industry Association

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technology environment. Bringing forth the issues on this level, Dr Sharma affirms, “Fresh graduates, many a times, may not feel comfortable with subject and/or industry during initial learning days. Due to this, they may even leave the company for new jobs. Also, training, absorption, and deployment of freshers is expensive, time consuming, and requires a lot of effort. Thus, training should be offered by in-house experts. But these trainings are generally not adequate as the trainers do not find sufficient time for preparing and delivering good training due to their normal work pressure. Another issue lies with smaller companies which outsource training. These trainings may not be of good quality or match with freshers’ needs.” Suggesting steps to address this, Wadhwa highlights,

“The competency gap can be overcome by creating a network of brand agnostic centres; our industry is ready to support aspiring educational institutions to fulfill this role as well.

Adding his thoughts, Mathoor elaborates, “The knowledge & skill set required for fresh engineers to work in industry in each sector are different. For example, when we think about process automation, we mainly look at skills needed with regard to DCS, PLC, SCADA, AMS, MES, SIS, F&G, Field Instrumentation, Final Control Elements, etc used in process industries. We should be aware that there are several organisations involved in development, engineering, project implementation and final use of instrumentation and automation systems for process industry, such as end user; design & engineering consultant; project management consultants; EPCs; main automation company (DCS/PLC/PAC); OEMs; system integrator; safety instruments/system manufacturers; field instrument/final control element/drives manufacturers; cable manufacturers; enclosure manufacturers, among others. Similar classifications are there for other areas of automation sector such as factory automation, building automation, etc.

“Unlike IT, we do not find training institutes who offer specialised courses which can provide necessary skill sets and make engineers industry-ready. Hence, need-based training programs should be arranged in-house by these organisations. These training programs should include sessions to make the beginners understand how their customers derive value from using their products or services,” Mathoor adds.

Sharing his thoughts, Belgur notes, “The training in industry has to start from internships during breaks as a part of the curriculum. Another way is to put them though a specific

finishing school process after completion of the curriculum and then to offer these students to the industry. The main competition would come again from the software units, who absorb students a year before they complete their curriculum.” Elaborating further he points out, “In my opinion, the policy group on education must insist that no company goes to any institution for campus recruitment. They all must have their internal assessment at their premises, so that students from all institutions get an equal opportunity.”

Attracting young talent

With the craze toward happening sectors like IT, management and other engineering verticals, how can the automation industry attract young talent? Highlighting on this front, Prabhu explains, “Career attraction depends on opportunities. The current student perception is that there are not many jobs in automation industry; these jobs are not well-paying; growth prospects are limited and job mobility to other areas becomes difficult since those who join the automation sector will be considered to have overly specialised experience and therefore, are not quite suited for other type of jobs. Unless this perception changes, it is difficult to make automation sector attractive.” Belgur adds, “The only way one can do this is to stop the policy of all software companies of coming to campuses and make them conduct their tests internally. The students need to be educated of the opportunities that exist for them in various sectors. Most students are unaware of their potential areas, where they can work.”

Highlighting the existing opportunities, Ayya says, “Today, opportunities available in Indian automation across various industry segments are growing due to various factors. One of the major contributing factors is that job opportunities in

“The automation industry must deem it to be its duty to reach out to

‘engineers-in-the-making’ in colleges” S S Prabhu, Professor (Emeritus), Advisor, IIITB

“The industry keeps adopting latest & diverse technologies quickly to stay in business, but the academia faces difficulty in keeping pace with the industry”Dr KLS Sharma, Advisor, Automation Education and Training

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“Job opportunities in automation are available due to capacity expansions in the manufacturing segment”Girish N Ayya, Consultant – Industrial Automation & Corporate Trainer and Co-Founder, Avadhoot Automation

automation are available due to capacity expansions in the manufacturing segment to meet the growing market demands. Another factor is that the addition/up-gradation of automation systems needs engineered manpower.” Commenting on the subjects in automation, Mathoor avers, “Instrumentation Technology – the name used in engineering colleges for this branch needs to change to represent today’s automation sector. The knowledge and skill set for today’s automation sector is not limited to instrumentation technology alone. It covers a broad spectrum of electrical sciences including electrical, electronics, digital communication, instrumentation, wireless technology, etc. So, why not use ‘Automation systems technology’ instead? The human resource departments in automation sector industries can and must learn from IT organisations on how to attract young talent. Clarity on career growth opportunities, campus selection and higher salary packages for beginners are few measures to start with.” Awareness about the integrated world of data and machines, challenging work environment and need of critical and analytical thinking are biggest attraction and strength of automation sector today. Wadhwa explains, “We need to show students how a smart manufacturing facility runs, the speed and reliability that automation technologies bring in and the operational analytics that give engineers and managers total control. This will give them excitement to join automation sector. We all know that a talented engineer wants to deal with physical processes, simulation and analytics. They want to apply their skills across multiple domains to deliver the best impact. Our industry offers challenging goals to make processes more efficient, robust and competitive. With new technologies coming up in automation, we can keep the passion of an engineer alive.”

Making industry-institute collaboration more productive

With education and training requirements taking the centrestage in the Indian automation industry, is there an enhanced need for industry-institute collaboration to be made more productive? Answering this, Wadhwa suggests, “We have to understand that both are part of a larger ecosystem. Educational environment and inputs are different from industry environment and inputs; so there must be a dialogue

to bring about an open sharing of resources. The biggest challenge for automation industry is to have people with cross-disciplinary skills. Institutes are usually department led, so the concept of open electives can be tried for teaching automation. By working with each other, we can solve this problem and produce competent engineers which are suitable and well accepted by both automation industry and user industry.”

Wadhwa provides the roadmap for industry-institute collaboration. It includes creating a balanced and brand agnostic industrial automation course that lays the foundation for engineers from different disciplines; creating opportunities for industry exposure; developing a network of colleges and industry partners that allow co-sharing of facilities; advocacy with AICTE and University Academic Councils to upgrade the core curriculum and assessment criteria; industry and colleges get linked through the creation of Competency Development Centres and on-line portal.

On a similar thought, Ayya adds, “To make the industry-institute collaborations more productive, the curriculum must address the basics regarding industrial measurements, control and process applications; all types of automation products like sensors, controllers, PLC, DCS, IT and automation integration, various automation standards used in the industry and industry standard communication protocol. Regarding the practices, the institutes can set up the labs using industrial products, so that the students can be exposed to industrial environments during the academics. During the degree/diploma courses, the integrated training programmes can be embedded to the respective semesters/years, so that the students can become well versed with the ongoing industrial scenarios.” Prabhu also suggests that the automation industry must deem it to be its duty to reach out to ‘engineers-in-the-making’ in colleges. ☐

“The policy group on education must insist that no company goes to any institution for campus recruitment. They all must have internal assessment at their premises”Renukaprasad Belgur, Business Mentor & Advisor, MentorWise Advisors and President of ISA (Bangalore Section)


Ready-to- install solution for the Automotive Industry

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ch e mical & p roc es s | Focus

a&D i nd i a | A p r-Ma y 201442

pervasive sensingPlants are being modernised with additional measurements, partly for the plant operator, but mostly for personnel outside the control room. The information helps increase reliability, energy efficiency, make the plant more environmentally friendly, and a safer place to work.

Jonas Berge Director, Applied Technology Emerson Process [email protected]



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Focus | ch emic a l & process

a& D i n d i a | A p r-M a y 2014

Your parents’ car likely had only four sensors: speedometer, the temperature gauge, fuel gauge, and oil pressure warning. Modern cars have multiple digital communication networks with dozens of sensors onboard for the drivetrain and brakes, for information, and for climate control. Most of the sensor data is aggregated into diagnostics used by the mechanic servicing the vehicle in the repair shop. Modern plants should be no different.

Plants face challenges such as personnel safety, environmental regulations, and energy costs. These challenges which are important to run the plant but are outside of process control and functional safety are referred to as ‘business critical’.

To solve these problems, plants are being modernised with additional measurements, partly for the plant operator, but mostly for personnel outside the control room. The information helps increase reliability, energy efficiency, make the plant more environmentally friendly, and a safer place to work.

Challenge

Plants already have a wired “primary layer” of automation for the process critical control and functional safety on the P&ID, providing operators at the DCS and Safety Instrumented System (SIS) consoles the data they need to run the plant efficiently and safely.

However, the reliability, maintenance, HS&E, and energy disciplines only get some of the data they need. There is a lot of “missing measurements” beyond the P&ID they have to collect manually or don’t receive at all, principally in the areas of asset monitoring for reliability, energy conservation measures for energy efficiency, and HS&E monitoring to reduce risk.

Measurement agility

Traditionally, many improvement projects do not get approval because adding sensor requires running signal and power wires for the transmitter risking to damage existing wires. Moreover, cutting and welding the pipe or vessel, could only be done during a plant turnaround. Wireless transmitters: The need for signal and power wires

are eliminated by WirelessHART transmitters, thus reducing the risk of damaging the installation and saving time. An electrician need not get involved either. A WirelessHART network only requires a gateway at the edge of the plant area. WirelessHART transmitters form their own infrastructure, a mesh network, also eliminating the need for expensive backbone routers and their associated power and network cabling. Intelligence wireless sensors form a web of powerful field devices, a digital architecture for the plant to improve performance - an industrially hardened version of the

“Internet of Things” (IoT).WirelessHART transmitters give the plant the agility to

freely add measurements because they can be deployed when required with little or no risk.WirelessHART is a digital signal, communicated in engineering units. A measuring range need not be configured in the transmitter or control system and there is no need to perform a 5-point loop check since there is no 4-20 mA signal. Non-intrusive sensors: Non-intrusive sensors mean no new process penetrations are created, reducing the risk and cost, and pipefitters need not get involved. For example, temperature sensors clamp onto the pipe. Acoustic sensors for steam trap failure, relief valve release, and passing valves are strapped onto the outside of the pipe. Position sensors for bypass and other valves bolt onto the outside. Vibration sensors are screwed or bonded to the equipment body. Fittings for pressure gauges are instead used for wireless pressure sensors.

Because applications beyond the P&ID are not as demanding as the safety and control on the P&ID, clamp-on temperature sensors are adequate in such applications. Similarly, a vibration transmitter is sufficient for non-critical

Table 1: areas of moDernisaTion

essential asset monitoring (eam)

Air cooled heat exchangers, blowers, compressors, cooling towers, heat exchangers, pumps

energy conservation measures (ecm)

Chiller water, compressed air, heat exchanger fouling, steam, steam trap failure

health, safety, and environmental (hs&e)

Gauges, sight glasses, variable area flowmeters, and dip sticks, grab sampling, manual and bypass valves, passing valves, relief valves, safety showers and eye wash stations, vibration, temperature, acoustic testers

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pumps and other equipment which don’t need an extensive monitoring system.

Beyond the control room

The DCS is not ideal for most measurements collected through pervasive sensing for the maintenance supervisors, reliability engineers, the HS&E officer, energy manager, and the steam trap service company because they do not sit in the control room. For them to disturb the operators to get their data and reports would be inconvenient for everyone.

System engineers are cautious with changes. There are policies and rigorous management of change procedures to get the control system configured to integrate a new and display measurement due to the process critical nature. It may be necessary for the system vendor’s service engineer to come to make the addition.

Asset management – the second system

Most pervasive sensing measurements are not process critical control or safety and therefore, do not go to the DCS and operators. Instead, plants deploy a second separate Asset Management System (AMS) with a suite of specialised applications for asset monitoring, energy management, and HS&E. Personnel from these disciplines access data from their own offices. Going to the control room to get the data or disturb the operators is not necessary.

Activation and health of safety showers and eye wash stations as well as relief valve releases, status of bypass valves and other valves, etc is useful to the HS&E officer. Which valves are passing, and to see data from vibration and temperature transmitters which take the place of handheld testers is useful to maintenance staff. Same goes for pressure,

temperature, level, and flow transmitters that take the place of manual rounds with the clipboard. Energy consumption for each unit to track conservation initiatives is useful to the energy officer who would also want to know if process equipment is fouling reducing their energy efficiency. The raw data from multiple sensors is aggregated into simple indicators of process equipment health and fouling to maintenance personnel for planning turnarounds and schedule daily maintenance.

Measurement agility includes ability to freely add a new measurement on the computer screen at somebody’s desk. Because the AMS applications situational awareness, energy efficiency, and asset monitoring, are not process critical they are much more flexible and open to changes than the safety and control system. On the AMS, the disciplines make the modifications themselves to suit their needs. Sensors can freely be installed, and the AMS configured to get the data onto a screen without disturbing the system engineers. Steam traps: Raw data from acoustic transmitters on critical steam traps throughout the plant is aggregated in steam trap monitoring software providing an overview of their health enabling the steam trap service company to quickly tend to steam traps before trapped condensate damages equipment or energy is wasted blowing steam.Reliability: In the reliability office, machinery health monitoring software enables analysis of vibration in pumps, motors, conveyors, and fans, etc from a WirelessHART vibration transmitter by reliability engineers using the same software used to manage critical turbines and large compressors.Maintenance, energy efficiency, and HS&E: For simple applications, standalone HMI software can be used.1) Maintenance: Passing valves, high vibration or temperature of equipment like pumps, fans, agitators, conveyors, and

Figure 1: Data from WirelessHART transmitters go to the control system and the AMS

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Figure 2: Steam trap monitoring software Figure 3: The AMS monitors process equipment like pumps

motors etc are flagged in standalone HMI software in the maintenance office. Readings previously taken manually from gauges, sight glasses, variable area flowmeters, and dip sticks, etc are collected automatically and printed in reports, eliminating rounds with the clipboard.

The health of pumps, heat exchangers, cooling towers, air cooled exchangers, and blowers, etc is computed using multiparameteric algorithms from raw data from sensors on each piece of equipment. This enables a data-driven maintenance paradigm. The work processes for maintenance personnel is to check the software first, before going to the field.2) Energy: In the energy office, software reports the consumption of steam, compressed air, and chilled water, etc for each plant unit to track energy conservation initiatives. Equipment fouling information is used by the energy efficiency officer to improve energy efficiency.3) HS&E: Standalone HMI software is ideal for displaying plant data in the HS&E office, used to reduce risk and help meet regulatory requirements. Software alerts when a safety shower or eye wash station is activated and keeps records of function testing. Relief valve releases are tracked. Similarly, open bypass or dyke valves, or other valves are flagged.

Plant historian – the third system

A Plant Information Management System (PIMS) aka “historian” is used for data collection in many plants. The plant historian is suitable for the pervasive sensing measurements. Algorithms can be created in the historian that aggregate raw data into actionable information for energy consumption tracking and asset monitoring, etc. “Big Data” refers to the historian’s tremendous capacity for data collection, long-term data storage and analytics.

Easy modernisation

WirelessHART coverage throughout process units and areas are now being installed in many plants to meet these business critical needs. Plant modernisation is adding automation where it didn’t exist before, and doesn‘t require system migration. New process critical data is integrated to the existing DCS while most data from the new sensors integrate with the AMS or historian. Plant modernisation using wireless sensor networks for a second layer of automation is a new business opportunity for EPC.

Don’t build your new plant old

Traditionally only process critical safety and control is automated in a plant. However, new plants should be built from the very beginning to support business critical needs, including an AMS with specialised applications and underlying wireless sensor networks. Do not build a new plant the old fashioned way.

The future for aging plants

Modern cars have been made more reliable, more fuel efficient, more environmentally friendly, and safer, using the many more sensors now networked onboard. Diagnostics derived from most of the additional sensors is used by the mechanic in the repair shop who has a different dashboard for servicing. Similarly, existing plants should consider deploying a second layer of automation for other business critical needs. A second system beyond the control room can assist the plant’s run and maintain organisation in making the plant more environmentally friendly, more energy efficient, more reliable, and a safer place to work. ☐

Projekt1 07.08.2013 14:59 Uhr Seite 1

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Downtime For saFe FUtUre operations A turnaround of two months is the most extensive chemical plant shutdown to date at the INEOS location in Cologne. Every day roughly 1,250 people work at the site, cleaning, maintaining and inspecting the extremely complex cracker plant. TÜV SÜD Chemie Service accompanies this mammoth project from the world of testing and inspection…



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a& D i n d i a | A p r-M a y 2014

A visit to the INEOS location in Cologne reveals labyrinthine futuristic structures tower in the distance. A closer look reveals hundreds of steel scaffolds serving as temporary, movable support structures and enveloping the 15-hectare chemical plant. The scaffolding provides entry to areas that are not normally accessible via stairs or fixed access ladders, including reactors, columns, heat exchangers, pressure vessels, control valves and other valves, and the many kilometres of piping systems. When in service, the plant processes or “cracks” naphtha, the crude-oil derivative used in the production of plastics for consumer products.

Now, the entire plant has come to a standstill – completely emptied, cleaned and opened for maintenance, servicing and inspection activities that cannot be carried out during normal operation. The turnaround covers all processing equipment, columns, vessels and piping systems as well as electrical safety devices and lifting equipment.

Biggest shutdown of all times

About 2,000 INEOS employees and another 4,000 staff from partner companies work around the clock. TÜV SÜD Chemie Service also has up to ten experts from various disciplines at the plant every day.

“With a total investment volume of €100 million including a modernisation programme, this is the biggest turnaround that our Cologne site has seen so far”, says Dr Anne-Gret Iturriaga Abarzua, Communications Manager, INEOS. Every five years, the plant is shut down for servicing and inspection. The experts from various disciplines then have just under two months to inspect all process-engineering equipment, columns, vessels & piping systems and the electrical safety devices and lifting equipment. In every plant turnaround, the experts also focus on identifying and realising additional opportunities for improvement.

Complex detailed planning

Realising such an extensive plant turnaround requires accurate planning to make sure that all activities, including the start-up procedures, are completed smoothly, without any frictional losses. The turnaround of this cracker plant required 75,000 hours of planning. The entire turnaround process, from rough outline to detailed schedule, is meticulously orchestrated. “Nothing is left to chance”, reports Marcel

Hohnroth, Turnaround Manager. “As time is money, we have planned every day of the shutdown, defining an exact route along which we walk the test engineers to the prepared components.” Preparations include dismantling and cleaning valves and vessels, uncovering and opening manholes, completion of any repairs that may be necessary and application of the defined test pressure to the heat exchangers so that the inspection engineers can get down to work without delay.

The turnaround

No matter who enters the plant, everybody first needs to be instructed on the necessary safety precautions and don the required personal protective equipment, including safety goggles and helmets, safety footwear, gloves and fire-resistant work wear. People who have attended the safety instructions are identified by a clearly visible sticker affixed to their safety helmet. In addition, everybody accessing the cracker plant needs an electronic ID security card which they must wear visible at all times. The inspection tour starts at a sort of container village near the plant. There, partner companies and clients have their own infrastructure including offices, storage rooms, communal rooms and rest areas. Tools and personal protective equipment too are handed out there.

Multiple backup documentation as a safety net

The atmosphere in the conference room of TÜV SÜD Chemie Service is focused and concentrated as inspection engineers and turnaround managers are discussing which parts and components will be next for testing and inspection. Around 1,000 items must be “checked off ” over the next six weeks. To complete this workload on time, the experts are working days, nights and weekends. “We inspect every single component”, explains Klaus-Dieter Peschel, Head – Plant Safety & Inspection, TÜV SÜD Chemie Service’s Dormagen location. The inspection engineer is in-charge of the team of experienced experts that work at the cracker plant. “We maintain a second documentation list in parallel to that of our client, to ensure no test item will be overlooked,” Peschel continues to explain. However, this is not all; the experts also review the list internally at the end of each day of the turnaround, thus extending the “two-man rule” to a “three-man rule”.

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Continuing through the container village, passing the catering tent and arriving at the plant check-in, all individuals entering the plant are registered at a computer terminal with the help of their ID security cards. Given this, the number of people currently in the plant can be determined at the click of a button. A security guard is waiting for us at the entrance to accompany us through the plant. There is a general air of bustle; everywhere we look, workers are grinding, welding or assembling parts. Everybody knows exactly what to do, and where and how long to do it. “In time-critical processes, well-coordinated maintenance and inspection schedules are imperative”, explains Peter Löffler, Inspection Engineer, TÜV SÜD Chemie Service. “By offering computer-aided management of inspection intervals and electronic access to inspection reports, we reduce costs and efforts incurred by plant owners/operators”.

Functioning order

Drizzle is now falling on the inspection engineers. Having inspected the inside of a vessel jacket, they are moving on to a heat exchanger connected to hoses and pumps. The hydrostatic test pressure briefly rises to 13 bar, and the expert from TÜV SÜD Chemie Service notes, “Component E-1050 withstands the test pressure, is tight and does not reveal any safety-critical deformation.” Once this has been determined, the engineer scrutinises connections, welds and particularly vulnerable spots. “The heat exchanger is in good condition. However, final approval must cover the component as a whole. Where are the hoods of the heat exchanger?”, the engineer asks the turnaround manager. After a quick call, the engineers proceed to a storage area where heat-exchanger hoods are lined up in a long and orderly row. There the experts find the hood they have been looking for.

Although the inspected and approved heat exchanger is on the small side, at a length of just under 4 m and a diameter of 70 cm it still weighs over 1.6 tonne. The weight is caused by the 80 tubes it comprises. By way of comparison, in other heat exchangers the number of tubes (known as the “bundle”) may amount to up to 10,000, easily bringing the total weight of the heat exchanger up to over 100 tonne. These types of component can only be moved by heavy-duty cranes. However, cranes are also needed for transporting smaller components to the right place. Given this, up to 40 cranes are in use at the cracker plant on any one day during the turnaround. A red crawler crane that can lift over half of its 927-tonne dead weight is particularly impressive. With a hook height of 188 metres, the crane is higher than Cologne Cathedral, and has warning lights on top to warn aircraft of its location. The crawler crane is the largest crane ever to be used in a turnaround on INEOS premises.

Modern test methods

Before proceeding to a stop valve, the engineers inspect another heat exchanger. At every component, the questions investigated by the experts are the same: Are there any indications of a corrosive attack or other damage? If so, what actions have to be taken? Does the component have to be replaced, or can its safe operation be guaranteed for another five years? What is the condition of other elements of the components, such as supports and insulation? Is there a risk of condensation developing? Have the necessary repairs, if any, been completed expertly? Sometimes special questions arise, necessitating further tests and inspections. “The technical progress made in non-destructive testing of surfaces by ultrasonic methods or digital radiography is providing new answers”, says Peter Löffler, TÜV SÜD Chemie Service. The methods supply high-resolution images of possible

Visual inspection of a raised manhole

uptime. anywhere.

Download our newIndustrial Networking Guideor visit www.redlion.net/NetworkGuide

© 2014 Red Lion Controls Inc. All Rights Reserved.

+91 - 9844876540 I [email protected] I better.redlion.netRed Lion, the trusted name in automation, now offers Ethernet and Cellular networking solutions. Connect, monitor and control virtually anything, anywhere.

Unmanaged | Monitored | Managed | Advanced Managed | Power over Ethernet

IP67 | Wi-Fi Radios | Cellular M2M Routers | Cellular RTUs | Communication Converters

From factory floor to extreme outdoor applications, Red Lionunderstands every network is not the same. That is why our newN-Tron and Sixnet industrial Ethernet switches, Wi-Fi radios and cellular devices are designed to meet diverse networking environments. Built-in redundancy coupled with robust reliability ensures infrastructures like yours stay up and running around the clock. Red Lion provides uptime anywhere so you can get the most out of your network investment.

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a& D i n d i a | A p r-M a y 2014


inhomogeneities in, say, welded materials, plant components or complex geometries. Depending on the diagnosis, they enable measures to be used that are better targeted to the specific problem on hand and that equally take into account the aspects of safety and cost-efficient maintenance.

Long-standing expertise

The inspection engineers rely on their expertise and their longstanding and specific experience. Having accompanied previous large-scale turnarounds of the naphtha cracker plant, they are familiar with the individual components and able to identify possible changes.

Starting from their in-depth familiarity with the plant, the engineers can also support the plant owners in other aspects during the turnaround, such as life-cycle or plant-expansion projects. “As third-party service providers, we not only take care of plant safety, but also help to maintain the value of the plant in the long term.” Our extensive experience with large-scale turnarounds enables us to offer high-quality, one-stop services to the chemical industry”, says Klaus-Dieter Peschel,

TÜV SÜD Chemie Service.At the end of this day of the turnaround, the experts have

found all components to be in perfect order. However, when they detect components that have to be repaired, time is of the essence. In this case, the plant professionals from TÜV SÜD Chemie Service provide further services – from defining the scope of repairs, providing the necessary calculations and approving the inspection and test plans to monitor the repair. All experts are working to one goal, ensuring the deadline for the startup of the cracker can be met.

When the day of the startup finally comes, the pressure in the plant is built up again and the cracker is brought to operating temperature. Fluids and gases flow into the system. Everything looks as if there had never been any large-scale turnaround at all. The tangle of support structures and scaffolding is dismantled, the cranes have moved on, and the chemical plant goes back to producing the basic chemicals for the world of tomorrow. ☐

Courtesy: TÜV SÜD Chemie Service

uptime. anywhere.

Download our newIndustrial Networking Guideor visit www.redlion.net/NetworkGuide

© 2014 Red Lion Controls Inc. All Rights Reserved.

+91 - 9844876540 I [email protected] I better.redlion.netRed Lion, the trusted name in automation, now offers Ethernet and Cellular networking solutions. Connect, monitor and control virtually anything, anywhere.

Unmanaged | Monitored | Managed | Advanced Managed | Power over Ethernet

IP67 | Wi-Fi Radios | Cellular M2M Routers | Cellular RTUs | Communication Converters

From factory floor to extreme outdoor applications, Red Lionunderstands every network is not the same. That is why our newN-Tron and Sixnet industrial Ethernet switches, Wi-Fi radios and cellular devices are designed to meet diverse networking environments. Built-in redundancy coupled with robust reliability ensures infrastructures like yours stay up and running around the clock. Red Lion provides uptime anywhere so you can get the most out of your network investment.

52

saf e t y & IN t e GRat ION | T E CH N OL OG Y


In today’s centrally configured programmable logic controllers (PLC), changes in individual plant sections have far-reaching consequences at control level, because program structures at central points in the control system have to be modified. In terms of flexibility, re-usability and user-friendliness, classic automation architectures with centralised PLC controllers can no longer meet future requirements. That’s why the automation of the future demands solutions that can distribute control intelligence but also guarantee that the necessary networking of multiple control systems remains easy for the user to handle.

Centralised view of a distributed system

Pilz developed the automation system PSS 4000. Whereas in classic automation a standalone, centralised control system monitors the plant or machine and processes all the signals, the PSS 4000 allows control functions to be distributed consistently. In detail, the automation system consists of hardware and software components as well as the real-time Ethernet SafetyNET p and various programming editors designed for use in different sectors, with their application-oriented function blocks. The hardware includes control

the laNGuaGes Of autOmatION

systems of various performance classes.Process or control data, failsafe data and diagnostic

information are exchanged and synchronised via Ethernet. For the control function, it makes no difference where the respective program section is processed. Instead of a centralised control system, the user has a program distributed in runtime within a centralised project. All network subscribers are configured, programmed and diagnosed via this software.

Transferring functions to the software

The transfer of functions to the software brings users flexibility and scalability, reduces the variety of hardware types and simplifies maintenance and diagnostics on automation solutions. The question as to whether software can be used efficiently depends essentially on the user interface and the available languages – both in terms of human language and programming language. PSS 4000 meets these challenges with the software platform PAS4000. Various editors and blocks are provided, which can be used for automation as well as safety-related tasks. In PAS4000, the tools for configuration, programming, commissioning and operation are closely compatible.

User-friendliness is the key to acceptance of automation solutions. But as the challenge of making operation clear & simple grows, automation tasks become more sophisticated. In terms of engineering, it’s not just the hardware but the software implementation that’s particularly important – and if possible this should be in the user’s native language. Users aren’t the only people to benefit: design engineers can also reduce their effort significantly.

52

54

saf e t y & IN t e GRat ION | T E CH N OL OG Y


The ability of users to use their normal native language is important in terms of acceptance. As a result, the PAS Editors in the automation system PSS 4000 are available in multiple languages other than English and German. One of the editors available to users in PAS4000 is the simple, block-based Program Editor PASmulti. PAS4000 also provides established editors for programming. These include editors for PLC programming (in accordance with EN/IEC 61131-3) for Instruction List (PAS IL) and Structured Text (PAS STL), as well as the new editor for Ladder Diagram (PAS LD). This can be used to create safety-related programs, programs for automation tasks or a combination of the two.

Different countries, different languages

The individual editors are used to varying degrees, depending on the country or region. While instruction list or structured text is frequently used for programming in Europe, structured text is usually favoured in Australia. Programmers in USA and Japan, for example, prefer to use ladder diagram. Within the Pilz automation system, the new Editor PAS LD can be freely combined with the other EN/IEC 61131-3 PLC programming languages, so that even complex automation tasks can be handled simply and consistently. All PAS Editors and programming languages have been classified as an LVL language (Limited Variability Language) by TÜV Süd, enabling users to resolve not only automation tasks but also safety-related tasks, without functional restrictions. So for the first time, machine builders can create safety-related application programs using their usual development process.

Open for all protocols

In addition to the interfaces for man-machine communication, data exchange within the automation project also has an important role to play. The same applies – the more complex and extensive the project, the more important it is to

have a standardised language. PSS 4000 also supports the diversity of language from a technical perspective: the control systems PSSuniversal PLC in the automation system PSS 4000 support the various communication protocols used depending on country and region, for example, the Profibus protocol, which is particularly widespread in Europe; Ethernet/IP, which is frequently used in the USA and Asia, as well as EtherCAT, CANopen and Modbus TCP. As a result, there is no problem exchanging data with the widest range of third-party control systems.

Simplifying the learning process

The increasing challenges faced by automation can be met using systems that can distribute intelligence but at the same time are user-friendly to control. As a result, the cost of engineering, commissioning and maintenance can be significantly reduced. The system’s openness and the wide range of languages make it easier to use in automation projects around the world. If local users can configure their machine in their native language and in their familiar programming environment, it simplifies the learning process and tool handling enormously, as well as increasing acceptance. For machine builders it brings the additional benefit of using one hardware structure, and a software program that needs generating once only, to create automation solutions that can be used anywhere in the world.

With the automation system PSS 4000, the control functions are fully distributed and transferred to the periphery. Control data, failsafe data and states are exchanged and synchronised via the real-time Ethernet SafetyNET p. Plants can be broken down into manageable, independently functioning units. As a result, the cost of engineering, commissioning and maintenance is significantly reduced. ☐

Courtesy: Pilz


The automation system PSS 4000 is suitable for all

automation tasks: from stand-alone applications to the

implementation of classic automation with a central

control system, through to the consistent distribution of

control functions to the periphery

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CO N T RO L & RE G ULAT ION | T echnology


Designing via a new technologyThe article details on breaking traditional boundaries and adopting new technologies for a machine builder by combining full feature sets and performance of fixed function devices

High performance machines often require specialised control algorithms and advanced synchronisation with sensors & vision systems. These requirements can be difficult to achieve with fixed function motion controllers & drives and turning to custom design often isn’t feasible. Thus, fully reconfigurable motion control architecture based on the combination of a FPGA, real-time processor and modular I/O can be used to implement specialised high performance systems more effectively than traditional approaches.

Motion control system architectures: reconfigurable vs traditional

Fixed function controllers and drives ship with firmware that implements behaviour which cannot be modified by the end-user. These controllers and drives could be optimised for a very specific purpose such as driving a CNC end mill spindle, or designed with the intent to be as generic as possible. As long as the operation is conducted within the designed use case, these fixed function controllers & drives are usually most effective for implementing an application because one can take advantage of all the design work and feature definition of that product, such as advanced filtering, auto tuning, test panels,

diagnostic tools, and so on.The problem with fixed function controllers arises when

the user, as a machine builder, steps outside the capabilities of a motion controller and drive firmware. Unfortunately, he may complete 95% of the application with a traditional controller or drive, but the remaining 5% abandons the entire design and so he searches for a new solution. These scenarios become more common as machines become more specialised and increasingly sophisticated.

Machine builders can also choose custom design. With a custom built motion controller or drive, builders can define their preferable behaviour from the system. However, custom design is costly, time-consuming and has its own set of limitations. They can be very challenging to build and manufacture with a full team of engineers with specific skills. They also include the burden of creating revisions for life-cycle management due to bugs or part availability which perhaps become the most important limitation. The result is a continuous cycle of custom design that is difficult to break, especially for smaller companies that need to be as agile and lean as possible in their operation. Alternatively, design and manufacturing can be outsourced to a third-party company, but it is expensive and exposes the specialised IP.

58



So, to combine full feature sets and performance of fixed function devices with customising them as needed for specified applications, one needs a persistent framework that can be developed through fixed function device with testing and iterative feature improvements. But since it is a modular approach, progression of computing technology and reconfigurable embedded design tools (specifically FPGA technology) solves the problem. The combination of a programmable real-time processor, programmable FPGA and modular I/O packaged into an off-the-shelf system adds much of the needed flexibility for building control and measurement systems. Taking this concept to software is also important. The ability to reconfigure a standard framework; customising where necessary but still utilising the rest is essential for machine builders. In this software architecture, motion tasks are disaggregated to choose where to run a particular task to meet the needs of the application. Furthermore, each task or block is open to modify the functionality down to a very low level. Finally, machine control software packages should be modularly constructed to modify the specific tasks and customise it without largely impacting other blocks in the system. This approach is to a large extent hardware agnostic, so that one can mix and match components to come up with the HW system that meets the axis count, processing power, integration with other I/O subsystems and level of customisability.

Specialised control algorithms

For systems that require non-standard control, having a reconfigurable system can make a difference between a simple

code-change and costly redesign. This is relevant at the drive firmware level in FPGA, as well as at the supervisory control level in the real-time controller.

One FPGA related example involves replacing common velocity or position loop with a loop running closed-loop force control. This can be done to test material strength, measure button quality or simulate a finger press on a touch panel. A modular design not only enables to use the control algorithm of your choice, but supports easy integration of a force sensor and any necessary signal conditioning. Other examples could include replacing hall-effect sensors with a custom startup routine for a brushless motor, or replacing a standard PID function with a more advanced control algorithm. For real-time controller, a modular design allows a developer to easily program their own inverse kinematics equations for non-standard coordinate spaces in addition to using the traditional trajectory generator. The real-time controller could also be used for other advanced tasks like using a model-based control algorithm.

Advanced synchronisation with I/O and vision

High performance machines will mostly require some synchronisation with other subsystems and this can take many different forms. Test systems may need to correlate data acquisition to specific real-world positions. Control systems often need to setup custom triggering based on a variety of conditions to perform tasks in real-time. Implementing motion on a platform with modular I/O means that one can mix and match specific I/O to meet system requirements without necessarily having to incur the cost of integrating a separate

The combination of a programmable real-time processor, programmable FPGA and

modular I/O packaged into an off-the-shelf system adds much of the needed flexibility for

building control and measurement systems

60



can dig in and customise just the pieces that one needs. By targeting specific portions of FPGA code for modification, one can achieve the needed flexibility and still get an application up and running very quickly.

The flexibility this approach provides is very powerful. One can use it to easily to achieve coordinated motion with a FPGA controlled drive and an external smart drive from two different manufacturers. One could also coordinate many different types of motors and use a different type of feedback for each, all without changing the existing trajectory generation or move profile software. Essentially, any functionality provided from modular I/O and an FPGA can be integrated into an axis of motion that can be integrated with other axes of wildly different configurations.

This technology is not always the best choice for every application; if the application is straightforward and it falls within the uses cases the large fixed function controller and drive manufacturers design for, one can probably design the system at a lower cost and more quickly using traditional motion systems. However, if one is pushing the edge with a high performance machine that needs to be better, faster, smarter than the previous designs, one will probably run into cases where advanced I/O, custom synchronisation, specialised control algorithms is needed or to integrate disparate or non-standard subsystems. Thus, one steps outside the boundaries defined by traditional devices and in doing so, a reconfigurable architecture becomes the most effective way to implement these systems. ☐

Courtesy: National Instruments

tool chain for the measurement I/O. Having an RT system with an ecosystem of available components means easier integration of motion, vision and I/O system components. Having a programmable FPGA allows custom hardware level triggering and signal analysis beyond what is capable on standard motion and automation platforms.

Perhaps the most common benefit FPGA provides in this architecture is the ability to define custom triggering based on information from the motion controller. For example, if one tries to precisely trigger a large collection of valves for precise durations at specific positions & features when implementing a printer-like application. This would likely be impossible with traditional motion architecture. However, once you combine modular IO with a high-speed FPGA that is aware of current position, the problem becomes relatively easy to solve.

A growing use-case for this synchronisation with real-time processors is vision-guided motion. The real-time processor can process image data, calculate positions and command those positions to motors configured in a coordinate space. This motion opens the door for a wide variety of exciting possibilities.

Integration of disparate motor/drive/control/feedback types

For lower level control, basically at the drive firmware level, one has the ability to use FPGA for a variety of common motion control tasks. These include control loops and commutation schemes, motion I/O like an encoder read, reading limit switches, implementing filters and so on. One > MORE@CLICK ADI03452 | www.AandD24.in

RIO architecture for motion control

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E N E RGY MAN AG EMENT | t e ch n ol og y


A variety of industry forces are driving the need among industrial companies for a comprehensive energy management system, but its profitability is motivating much of this activity. Organisations are realising that sustainability initiatives alone cannot drive profitability. They are finding that energy management efforts must be combined with efficient operations to effectively drive long-term financial growth.

However, two key challenges — lack of visibility into key performance indicators (KPIs) and a legacy manufacturing IT environment are preventing many companies from achieving their financial and operational goals. Investing in Energy Intelligence software, which includes data collection, visualisation software and analytical tools, is one way in which organisations are beginning to address their challenges. In many cases, this software supplements existing and planned manufacturing operations management (MOM) software and automation investments.

However, these technologies traditionally neglect to collect and manage energy data in context of operations, so many companies are beginning to deploy Energy Intelligence strategies to gain insight into the role of energy within their operations — from procurement through production.

In addition to operational insights, the data generated by this technology is being used to provide improved clarity for

Taking eco-conscious decisions intelligentlyA read into Energy Intelligence software that helps companies to achieve sustainability and energy-management objectives by delivering data across the enterprise

buy/produce decisions and to help justify energy efficiency projects. However, energy data alone cannot drive success. The information generated by this technology must be paired with the right energy-management processes and organisational leadership capabilities. By uniting all these elements, firms can begin to develop a more holistic and effective strategy that turns energy data into actionable operational insights.

Overcome obstacles

Macroeconomic trends such as global population growth and GDP expansion certainly are driving the need for cleaner, more cost-effective energy sources. These trends have prompted individual companies to target energy projects aimed at reducing consumption and improving sustainability.

In addition, although financial growth is a top business objective for executives in the coming year, according to a survey from LNS research, companies are not necessarily tying sustainability and energy-management programs to this goal directly. Instead, sustainability and energy-management programs more often are tied to profitability improvements and energy usage reductions. Top sustainability objectives for 2013 include reducing the total cost of operations and reducing energy consumption. The top goal for energy management

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technology | ENER G Y MANAGEMENT

A& D I n d i a | A p r-M a y 2014

• Seek support from senior leadership: This backing is imperative for success because it often acts as a catalyst for creating an energy-focused culture and an effective Energy Intelligence software implementation.

• Take advantage of existing energy-management programs: These programs, such as ENERGY STAR, ISO 50001 and Superior Energy Performance, can serve as a helpful resource for understanding industry best practices and developing methodologies.

• Take a next-generation approach to manufacturing software: Using a common information management system for energy data can help alleviate past problems related to measuring energy data and transforming it into operational insights.

• Use role-based KPIs: Energy Intelligence software standardises data sources in a way that allows everyone from executives and decision-makers to the shop floor to identify specific areas for improvement and measure progress toward goals.

While more environmentally-conscious decisions will be expected by stakeholders over time, the operational and financial benefits of Energy Intelligence software warrant enough evidence to take action now. ☐

Courtesy: Rockwell Automation

also is reducing the total cost of operations. Executives also want to align their energy programs and operations with corporate sustainability objectives. Companies face a variety of challenges in reaching these objectives, but the top issues cited by executives both were related to technology. It includes disparate systems and data sources. Purpose-built applications often are implemented piecemeal by individual divisions or business units, so systems lack cohesion and strategic purpose. Energy metrics are not measured effectively. The proliferation of disparate systems makes it difficult to share data across the enterprise and make measurable improvements.

Connecting people, processes and technology

Energy Intelligence software has made it easier for companies to achieve their sustainability and energy-management objectives by delivering data across the enterprise. The software brings together energy and production data so it is possible to view energy consumption by process or product, and even allocate energy costs to the bill of materials. However, technology investment alone is not enough. Companies must align and optimise key resources that include people, processes and technology. Instituting a few best practices in these areas can help ensure the technology investment reaches its full potential. > MORE@CLICK ADI03453 | www.AandD24.in

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se n so rs & e n coders | T E CH N OL OG Y

A&d I nd i a | A p r-Ma y 2014

Advancements in micro-machined inertial sensor technology are enabling revolutionary improvements in industrial system designs. Applications including industrial vehicle navigation, platform stabilisation, robotics and condition monitoring are increasingly reliant on multiple sensors to attain system objectives. However, there are barriers to overcome for obtaining these benefits, particularly in tough physical environment of many industrial applications, where temperature, vibration, limited space and other factors must be addressed. Extracting consistent data from the sensor, translating it into useful information and reacting to it within the system’s timing and power budget requires expertise on the part of the designer in many technology domains.

BuIldIng desIgner expertIse

Understanding the problem

Information from inertial sensors can be processed to derive different types of motion, position and directional outputs. An appropriate example of this is industrial control applications, where some form of pointing or steering of the equipment is useful. Tilt or angular sensing is often at the heart of such applications and in its simplest incarnation a mechanical bubble sensor may suffice. However, before specifying the sensor needs; the full motion dynamics, environment, life cycle and reliability expectations of the end system need to be analysed. Many systems involve more than one type of motion (rotation plus acceleration, for instance), and quite often

The article deals with the revolutionary leap of industrial system designs through the use of latest sensor technologies, and the expertise required to reap the benefits of this evolving technology

64

Bob ScannellBusiness Development ManagerMEMS/Sensors Technology GroupAnalog Devices Inc

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TECHNOLOGY | sen s or s & encoders

A& d I n d i a | A p r-M a y 2014

operate on more than one axis, thus driving the need to consider combining multiple sensor types. Once the proper sensor types and technology are known, the challenge shifts to understanding and ultimately compensating for the sensor’s reaction to the environment.

Inertial sensor component: Linear rate & angular rate sensors

There are several kinds of inertial sensors. MEMS (micro electro-mechanical systems) sensor technology is among the most well-established, and has brought benefits to a wide range of applications. MEMS linear rate sensors (accelerometers) has revolutionised the automotive-airbag-system industry 20 years ago. Since then, they have enabled unique features ranging from hard-disk protection on laptops to more intuitive user-motion capture in game controllers. On the other hand,

angular-rate sensing is also available from MEMS structures based on resonator gyro. Sensing structures are electro-statically driven to resonance, produce the necessary movement to create a Coriolis effect during rotation. At the outer extremes of each sensing frame, movable fingers are placed between fixed fingers to form a capacitive pick-off structure that senses Coriolis motion.

Sensor fusion for complex motion

Generally, a device’s motion is relatively complex (more than one axis), which drives the need for full inertial measurement units and integrate up to 6 degrees of freedom of inertial movement (3 linear and 3 rotational). Mostly, four or more additional degrees of freedom may be integrated, including 3 axis of magnetic sensing and 1 axis of pressure (altitude) sensing. Beyond ‘filling the gap’ for guidance when

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se n so rs & e n coders | T E CH N OL OG Y

A&d I nd i a | A p r-Ma y 201466

GPS, optical or other interferences are present, the highest performance inertial sensors can potentially provide continual guidance, free of reliance on such external inputs. With momentum behind small, low power, multi-axis inertial sensors for consumer applications, there is an equally significant need for high accuracy. These high accuracy, environmentally robust sensor developments are driving a new surge in the adoption of MEMs inertial sensors.

Integrated signal conditioning and sensor processing

In the industrial market, applications such as vibration analysis, platform leveling and general motion control need highly integrated and reliable solutions. It is also important to provide sufficient control, calibration and programming features to make the device truly self-contained.

Since the industrial sensing market is incredibly diverse, it requires a wide range of performance, integration and interfaces accommodated through integration of embedded tunable features such as digital filtering, sample-rate control, condition monitoring, power-management options and application-specific auxiliary I/O functions.

A linear acceleration specification of 0.1 degree/second/g, for instance, adds 0.1 degree of error to the bias stability spec of 0.003 degree/second, in the simple environment of rotation through +/-90 degrees (1g).

Thus, optimising sensor performance and minimising development time requires intimate knowledge of both sensor sensitivities and application environment. The calibration plan can be tailored to address the most influential elements, and thus minimise test time and compensation algorithm overhead. Harnessing acceleration to provide vibration analysis

To facilitate sensor deployment in remote and rugged environments, embedded wireless connectivity can simplify the deployment of the sensor network at a significantly reduced cost. The ability to detect and understand motion has the potential to add value to nearly any conceived application. It helps to harness the motion that a system experiences and translate that information into improved performance; enhanced safety or reliability or other added-value features. These features or performance upgrades are often implemented on existing systems. The small size and low power aspects of MEMS inertial sensor components is attractive given that the end-system’s power and size envelope are already fixed, or must be minimised. However, in some cases, designers of these systems are not motion dynamics experts, and thus the availability of fully integrated and calibrated sensors can be essential in choosing to proceed with these system upgrades. ☐

The figure shows inertial

navigation system, merging

multiple sensor types with the

aid of Kalman filtering


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68

E V E N T | P R EV I EW


Auotmatica 2014 will be held from June 3 to 6, 2014, in Munich, Germany. The event is organised by Messe München GmbH and VDMA Robotics + Automation with the aim to present the entire value-added chain in robotics and automation. It is the leading platform for innovations in automation and production processes, and has the world’s largest range of robotics, assembly and machine-vision solutions. Companies from all branches of industry will attend the event to find future-oriented solutions and manufacture higher-quality products more efficiently. It is the perfect place to gather information about the latest developments, find solutions to new challenges, make contacts and effectively invest in technologies of the future. The exhibition sectors will include assembly and handling technology; control-system technology; robotics; professional service robotics; security technology; machine vision; supply technology; positioning systems; software and drive technology.

Robots for metalworking

The two topics to be demonstrated during the event will include automation of machine tools and special robots for metalworking. “Robots are taking on increasingly complex work content all the way to complete machining, often equipped with automatic gripper replacement systems. In addition, solutions are increasingly in demand, in which robots not only automate machining centres, but also handle linking of production systems and consequently provide even more autonomy,” said Manfred Hübschmann, Managing Director, Stäubli Robotics. Kuka will present Waterproof models of the recently started KR Agilus series during the event. “Stable stainless steel covers, special surface treatments and numerous gaskets enable unrestricted use of our small precision robot in machine tools,” said Andreas Schuhbauer, Key Technology Manager, Kuka Roboter GmbH.

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Platform for automated processesAddressing solutions to new challenges, effectively investing in the latest technologies and providing a roadmap to the future-oriented solutions, Automatica 2014 will be held from June 3 to 6, 2014 in Munich, Germany. A preview…

69

PR E V I EW | EVENT

A& D I n d i a | A p r-M a y 2014

Platform for automated processes

Automatica 2014 will present

innovations to the international

automation industry that

are based on changes of

production technologies in the

automobile industry

The development departments at ABB, Fanuc, Epson, Yaskawa and other robot manufacturers are also working on this topic, so that additional pioneering innovations can be expected at Automatica.

Solutions for the food industry

The food industry is one of the biggest growth markets of the automation sector. Regardless of whether manufacturing of food, primary or secondary packaging, automation is the trend. At Automatica, exhibitors will present the latest developments and pioneering solutions for efficient and controlled, safe production methods for food.

A look at the numerously implemented projects shows how far automation has progressed in the food sector. Robots milk cows, slice cheese, sort bakery goods, pack lettuce, palletise beverages – to put it short, there is hardly any process that can be imagined without them. Regardless of whether bakery goods, pasta, confectionery, meat, fish, dairy products, frozen food, fruit and vegetables, whether filling, dosing, cutting, labeling or during picking, packing and palletising, automated solutions ensure output and savings.

The innovative force and dynamics of the industry are surprising in this respect. The comparison of state-of-the-art systems, which have already been in operation for several years, with that of current high-performance lines, as they can be seen at Automatica, make it clear: significant improvements have been achieved in all relevant criteria such as cycle times, availability and energy efficiency thanks to development work. Delta robot kinematics and ultrafast pickers score with more than 200 picks per minute. Modern production lines achieve output that was considered inconceivable only a few years ago.

Focus on automobile production

Lightweight construction is on the agenda in automobile production, but the struggle to reduce every kilogram of weight possible presents challenges to production strategies. New production processes and technologies are required if light construction concepts are to be viable with respect to costs. The event will present innovations to the international automation industry that are based on changes of production technologies in the automobile industry. Automation in the production of lightweight components is a pivotal topic at Automatica 2014, above all in the area of composites. The special exhibition “Automated Composite Production” and the

“Industrial Composites Production Conference” in the East Press Centre from June 5-6 will examine state-of-the-art technology for increasing process speed and reducing production costs.

Energy efficiency & sustainability

The automation industry is working intensively on its own energy transition. Assembly systems, processes, robots and components are being tweaked consistently to be more energy efficient. Automatica is presenting pioneering technologies and the most recent developments for especially economical and sustainable production.

The complexity of the topic shows how important knowledge about the latest components, processes and technologies is for sustainable production. Automatica provides trade fair visitors with a wide range of energy efficiency topics with the presence of leading manufacturers as well as the VDMA sustainability initiative Blue Competence. ☐

Courtesy: VDMA> MORE@CLICK ADI03455 | www.AandD24.in

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E V E N T | r ep ort


Hannover Messe 2014, the world’s leading trade fair on industrial technology was held on April 7-11, 2014, at Hannover, Germany. This year’s edition had a strong emphasis on industrial automation & IT; energy & environment technologies; industrial subcontracting, production engineering & services; and research & development. The trade fair attracted nearly 1,80,000 visitors from over 100 nations. Another standout feature involved the high percentage of industry professionals, top buyers & decision-makers among the attendees. “The industrial trade show addressed the key issue of the future of industry by presenting solutions needed for tomorrow’s intelligent factories,” commented Dr Jochen Köckler, Member of the Managing Board, Deutsche Messe.

Highlights

Staged under the keynote theme of “Integrated Industry – NEXT STEPS”, the trade fair focused on intelligent, self-organising factories and the transformation of energy systems. Dr Dietmar Harting, Chairman, Hannover Messe Exhibitor Committee, stated, “Hannover Messe is where digitised, integrated industry is putting down roots, before growing into a mighty tree. This is the starting point for driving industrial advancement in countries around the world.”

“The many and varied exhibits of Industry 4.0 plant and machinery made the coming industrial revolution a tangible reality for those in attendance,” said Köckler. A large number

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CoNVENTIoN of globAl INNoVATIoNsHannover Messe 2014, the mega trade fair on industrial technology, was held recently at Hannover, Germany. With multiple new innovations and product launches, visitors explored the future of industry and invested in the latest factory & energy technologies displayed during the show by over 5,000 exhibitors in 16 halls. A report from the fairgrounds…

Sumedha Mahorey Deputy Editor [email protected]

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CoNVENTIoN of globAl INNoVATIoNs

of demo installations gave visitors a first-hand view of products moving through the various stages of production without any human intervention until individual processing at the very end. Data security was another core issue at the fair. “Forum debates on process and data security issues attracted several thousand visitors, and industrial businesses will definitely be cooperating more closely with international cyber security providers, to prepare factories for the extensive integration that lies ahead,” noted Köckler. The focus of attention in the

“energy halls” was on the transformation of energy systems. Future growth in the use of renewable forms of energy, decentralised energy supply systems and intelligent distribution systems were high on the agenda. Exhibitors presented technologies and solutions for the ongoing energy transition, with displays lending firm shape to the energy systems of the future. Highlighting on the country-wise participation, Marc Siemering, Senior Vice President, Deutsche Messe, said, “This year, we had more than 500 exhibitors from China; 250 from Italy, Turkey & Netherlands, followed by participation from the US, France and Poland. We have also seen increase in participation from some parts of Europe like Spain as the economy is moving towards the positive. This has not only positively affected exhibitors’ turnout but also the visitors.”

Events

Many conferences and forums were held during the trade fair to highlight on the networking of automation and IT, process automation, energy and resource efficiency, robotics and system integration, along with clever systems solutions for assembly and handling. The topics also included progress in materials research and lightweight construction to transform machine-building in far-reaching ways. These forums helped learn about the solutions already on the market in the industrial supply, production technologies, services, among other areas. Many forums were also held to discuss research, development and technology transfer in an international context.

publish-industry Verlag, in official cooperation with ZVEI invited owners, managers and representatives from top management and senior management of leading companies & organisations at the VIP Talk on the RED COUCH. Chief editors of the PI expert media and Kilian Muller as Publisher and Editor spoke live with these experts on subjects that move the industry.

The awards presented during Hannover Messe included Hermes & Robotics Award. SAG GmbH won the Hermes Award for its iNES product, an intelligent distribution grid management system that can be used to convert conventional local grids in stages into smart grids. While the 2014 Robotics Award for excellence in applied robotics was won by Austrian firm KEBA AG for its new way of positioning and programming mobile robots. The “KeTop T10 directMove” developed by the company is a new breed of handheld robot controller for positioning, guiding and programming mobile robots.

Initiatives in India

While highlighting the launch of a new show in India, Dr Andreas Gruchow, Member of the Board, Deutsche Messe AG, averred, “We will be organising CeBIT in India this year. Another show, ‘Plugged In’ will be held simultaneously at the same venue.” Providing details of the new show, Mehul Shah, MD, Hannover Milano Fairs India, highlighted, “We are organising CeBIT on November 12-14, at BIEC, Bengaluru. In a B2B format, the central theme of the show will be “New perspectives in the IT business”. We will be focusing on the four forces in terms of trends in the IT business. The sectoral focus will be on social, mobility, Big Data and the cloud and the exhibitors will be clustered into eight different sectors. Considering that CeBITin India is also the only CeBIT in Asia, there is a lot of business technology buyer interest from Asia Pacific, Japan and GCC which will add an Asian flavour to CeBIT in India.”

“This year, we had more than 500 exhibitors from China; 250 from Italy, Turkey and Netherlands, followed by the US, France and Poland”Marc Siemering, Senior Vice President, Deutsche Messe

“The central theme of CeBIT in India will be – New perspectives in the IT business”Mehul Shah, MD, Hannover Milano Fairs India

“We will be organising CeBIT in India this year. Another show, ‘Plugged In’ will be held simultaneously”Dr Andreas Gruchow, Member of the Board, Deutsche Messe

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Exhibitors’ viewpoint

While elaborating on this year’s response at Hannover Messe 2014, Sandeep Saheta, Director – Sales & Marketing, Connectwell Industries, said, “This year’s Hannover Messe has been exciting enough. We consider it as a platform to showcase our products to visitors from world-over. This year has also been successful on this aspect. People come to us being an Indian company with an Indian manufacturing base for alternative, cost-effective and reliable options. We continue to see good demand from Eurozone customers. On the technology front, in connection technology, there has been a definite shift toward faster and safer connections. We are addressing these technology shifts by launching products that meet the ever changing expectations of customers globally. This year, we have launched the new CX Series spring clamp terminal blocks which is more compact and efficient with higher voltages.Also, to cater the solar industry, we now have 1,000 volt spring clamp terminal block. This is an offering that we would roll out across the globe in the coming months.”

Affirming good demand at the fair, Ashish Manchanda, MD, Finder India, said, “For us, the response has been very good. Right from Day 1, we have had many footfalls and quality people who meant serious business. This is the kind of platform that makes new innovations successful. It also brings many Indian visitors to Hannover.” On the technology trends witnessed during the show, he asserted, “The technologies displayed this year are very encouraging. People are willing to spend money on innovations which is apparent from the overall dimension & variety at the show.” Highlighting the new launches and response from various sectors, Manchanda pointed out, “This year, we have launched 11 new products. Primarily, we have seen more demand in the power, O&G and building infrastructure sectors. Everybody is quite encouraged as business has been better in the first quarter of 2014.”

For some, the show was not as good as for many. Vijay Kambe, Partner, KB Electronics, noted, “We are displaying programmable power supply, a cost-effective solution with equally good reliability. We have also displayed solar pump controllers and solar MPPT chargers for the European market. The response that we have got at the show is not good so far. We have found that this time the number of participants & visitors are less. Our experience with EEPC has not been very good. Next year, since India is the host country, EEPC should better get their show together.”

The association angle

India’s representation at Hannover Messe has been consistent over the past years. Elaborating on Indian participation, Capt VW Katre, Member, Executive Council, IEEMA, said, “Members have come on their own at this fair, sometimes with reference from IEEMA or as part of EEPC. Most of the Indian manufacturers come here with a purpose to seek technology rather than to provide it. To the best of our knowledge, some of our members in the past have been able to formulate either a technology transfer, or a joint venture at this fair. We are here to identify the technologies that can be modified and brought into use in the Indian urban infrastructure development. Even though this is an extraordinarily vast field, we have identified technologies in the areas of smart grid, solar power, LEDs for lighting systems, more intelligent usage of power through technology deployment at this year’s Hannover Messe. We also have an ongoing dialogue with ZVEI to discuss newer thought processes, innovations and technologies.”

With multiple forums, innovations and product launches, this year’s Hannover Messe turned out to be the key event for initiating the technology curve for integrated industry in the following year globally. The next Hannover Messe will be staged on April 13-17, 2015. ☐

“People come to us being an Indian company with an Indian manufacturing base for alternative, cost-effective and reliable options”Sandeep Saheta, Director – Sales & Marketing, Connectwell Industries

“The technologies displayed this year are very encouraging. People are willing to spend money on innovations”Ashish Manchanda, MD, Finder India

“We are here to identify the technologies that can be modified & brought into use in the Indian urban infrastructure development”Capt VW Katre, Member, Executive Council, IEEMA


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Automation Industry Association (AIA) had recently organised a forum on “Leveraging technology for quantum jump in business” in Pune, in partnership with by Wisdom Solutions and Maharatta Chamber of Commerce Industries & Agriculture. The purpose of the event was to inspire SMEs to view the tangible benefits and opportunities offered by new technologies to grow business opportunities.

Future of manufacturing industry

Anup Wadhwa, Director, Automation Industry Association, facilitated a presentation of three case studies focused on automation by practitioners from the SME segment.

In his opening remarks, he spoke about ‘Reshaping the future: transcending barriers with real time acumen’. He pointed that future manufacturing industry will be about convergence of technologies and intelligent collaboration of the entire ecosystem. He discussed how knowledge islands are

synchronising and various processes inside and outside the plant are interconnected and interdependent from production to shipping. The entire business system is based on innovation partnership from strategy to execution which needs real-time acumen comprising of business acumen, operations acumen and process excellence. This discussion highlighted the following benefits:Efficiency and compliances: Increase throughput, reduce cost, improve accuracy and reliability and reduce human fatigue and human interference.Process improvement: Enhance productivity, improve quality and consistency, to work in areas unsafe for human operation, easy verification, validation and tracking.Business transformation and performance: Experiential transformation, provides real-time feedback to align sales and marketing and allows response capture and lead nurture; increases customer satisfaction and brand perception; and improves productivity of overall organisation.

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Building an idea factoryShowcasing latest trends in automation technologies that offer concrete solutions to aspiring SME manufacturers who are looking for innovative ways to compete in the global economy, Automation Industry Association (AIA) in partnership with Wisdom Solutions and Maharatta Chamber of Commerce Industries & Agriculture, had recently organised a conference on “Leveraging technology for quantum jump in business” in Pune. A report…

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Building an idea factory

Baxter common sense robots in the

future are expected to meet with

self-learning robots specifically

designed to be affordable for

mid-size and small manufacturers

Case study 1

During the conference, Pradeep Bhalwankar, MD, Twin Engineers, shared his journey of automation enabled machines, and concluded with a fascinating video of the Baxter common sense robots. “Twin Engineers, for many years restricted itself to installations that were in close proximity to Pune because the service needs were heavy. By embracing quality automation components it developed machines of superior capability that were customised for auto majors in South and North India. We also ventured in export markets as the machines they make can be serviced easily via remote diagnostics,” he said. As per Bhalwankar, multi-axis movement in future will meet with self-learning robots specifically designed to be affordable for mid-size and small manufacturers. New trends in automation technologies offer concrete solutions to aspiring SME manufacturers who are looking for innovative ways to compete in the global economy.

Case study 2

Another highlight was the powerful presentation of smart automation of a milk plant by Vishwas Chitale, Partner, Chitale Dairy. He spoke about Business Process Automation (BPA) which focuses on running the business perspective to automate, monitor and analyse process model by executing, controlling and optimising the various processes. BPA often deals with event driven, mission critical and core processes. Processes like animal data recording, buffalo feeding, breeding and milking and how they are successfully integrated, controlled and managed by smart automation system at Chitale Dairy were showcased during the presentation.

Case study 3

During the conference, an interesting presentation was given by Uday Mehta, MD, Sunrise Computer Systems, on how ‘One plus one equals eleven’. He discussed the importance of e-learning and how he embarked a new journey of developing a strong e-learning platform. Then, after two years when e-learning became a very common platform, he looked at a new dimension and his brainchild Maharishi Augmented Reality Domain (MARS) was born, integrated with mobile technology for learning and evaluation. MARS connects real world to digital world by understanding the complex structure and working of human brain with the help of sensors. The possible applications of MARS include trainning unskilled workers in new skills set within the factory, in technical/industrial schools, at dealer’s location or in the overseas plants of multinational companies.

Toward a quantum business jump

Nitin Ahir, Senior Trainer & Head Coach, Wisdom Solutions, explained technology as an initiator and how it can be used for catapulting team productivity and efficient collaboration. He discussed how the technology is currently under-utilised and the business owners are undoubtedly missing huge opportunities of growth due to this. He concluded by suggesting that we need to make up a choice about using technology if ever we need a quantum business jump in business. The conference addressed various ways of leveraging technology and reiterated its strong application in the manufacturing sector. ☐

Courtesy: Automation Industry Association> MORE@CLICK ADI03457 | www.AandD24.in

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Tyre manufacturing industry plays an integral role in the transport sector. The Indian tyre industry has witnessed a tremendous growth for the past few years. In fact, availability of raw material (natural rubber) and ultramodern production facilities has led the country to emerge as one of the world’s most competitive tyre markets. According to Indian Tyre Industry Forecast 2015, the tyre production in India is anticipated to reach 191 million units by the end of FY 2016. Moreover, manufacturers are expected to invest huge amount into the industry over the next few years, with a major proportion of this investment directed toward the radial tyre capacity expansion. Tyre manufacturers in India are evolving greatly in terms of latest technology innovations.

Lapp India has supplied superior quality cabling solutions for a leading global tyre manufacturer specialising in slow moving vehicles which is considered to be the world’s largest manufacturers of tyres for material handling and load handling vehicles.

Solution requirements

The prime requirement was cabling solutions for large scale maintenance purposes in various crane and drag chain applications to transport raw materials and finished goods from one part of the factory to another; machines with parts that have to go through constant motion which will require remote controlling and trolley systems.

The tyre manufacturing company required cables that can resist high temperatures of the tyre manufacturing factory and be dirt/dust resistant. Additionally, they also needed single core and multi-core heat resistant cables which

The tyre manufacturing company required

cables that can resist high temperatures of

the tyre manufacturing factory and be dirt/

dust resistant

ROuGH & TOuGH CAbLEsSuitable cabling solutions are necessary for tyre manufacturing factories to withstand high temperature & harsh operational conditions

can safely be used in harsh operational conditions.

Flexible cables for high movement applications

Since the crane systems undergo constant movement, Lapp India provided cables that are flat and are highly flexible and durable, making them ideal for high movement applications. These cables maintain high standards as they are flame retardant and can withstand high temperatures.

For trolley systems, the company supplied cables that are ideal for locations with space constraints. They are highly flexible and are also capable of withstanding harsh environmental and operational conditions. These cables are made up of strands of bare or tinned copper wires with rubber based core insulation. Additionally, the cables also have individual core screening consisting of tin-plated copper braiding and plastic foil wrapping. The copper braiding screens the cable against electromagnetic interference.

Heat resistant cables

For these applications, Lapp India supplied silicon cables ideal for locations which have high ambient temperatures and where insulating sheath materials of conventional cables will embrittle after a short while. The cables comprise fine wires with tinned copper conductor. They have silicone based core insulation with a twisted and layered core. The cables also possess a silicone-based outer sheath. Moreover, these cables are halogen-free and flame-retardant and are resistant to oils, alcohols, vegetable and animal fats and chemical substances. > MORE@CLICK ADI03458 | www.AandD24.in

The company also provided conduits to offer additional protection to cables used in the drag chain. These conduits are dimensionally stable and offer high resistance to oil, petrol, acid and grease. The conduits are air tight and impermeable along with the added features of being halogen and calcium free.

Key features

The cables possess special features like weather-resistant flat rubber cables with copper screening, copper braiding screens the cable against electromagnetic interference and the flexibility simplifies installation where space is limited. The cables are made of silicone-based outer sheath halogen free and are flame retardant adhering to highest industry standards VDE/IEC. Extended temperature range of -25°C to +90°C with core insulation rubber compound and possesses insulating properties after combustion due to remaining SiO2 ash on the conductor. ☐Courtesy: Lapp Cables

n e w s | technology

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Safety light curtains

contrinex’s Safetinex light curtains consist of a sender and a receiver

unit which, by exchanging sequential coded

infrared rays, create a protective field

between them. A safety relay connected to

the AOPD (active optoelectronic protective

devices) sends signals to the machine

controller. Correctly installed, the light

curtain detects any intrusion into the danger

zone, activates the relay and thus, ensures

an emergency stop of the system concerned.

The distance between sender and receiver,

as well as the dimensions of the optics,

determine the size of the protective field.

Safetinex YBB light curtains are ideal for

finger and hand protection. For the

access protection of larger areas, the

Swiss specialists offer the YCA

multi-beam photoelectric sensors. These

curtains have a resolution “R” of 14 mm

for finger protection or 30 mm for hand protection. “R” is the sum of the

distance of the beams from each other (i) and the effective diameter of a

beam (b): R = i + b.

Automation solution for packaging

B&R has developed reACTION and NetTime technology which reduces

response times in industrial automation

applications down to 1 µs, allowing

extremely time-critical sub processes to

be managed using standard hardware

within IEC 61131 requirements.

The performance of high-speed machine

functions such as product labelling or

rejection of sub-par products has also

gained an enormous boost – without

added costs – through such

technologies. Packaging lines demand

extreme levels of productivity and

flexibility across the board - from the

primary and secondary solutions straight through to the end-of-line

equipment. This can be achieved through a modular design with control

and drive components installed directly on the machine‘s frame - or even

on rotating parts. B&R combines maximum performance, extreme

flexibility and real openness with IP65-rated ACOPOS remote servo drives

and ACOPOSmotor motor-integrated servo drives, and X67 series of

machine-mountable I/O and safe I/O modules.

Terminal blocks to fight vibration

connectwell has recently launched three terminal blocks STH3, STH4 and

STH6 that are preferred for application where the connections are

subjected to severe vibration. Here, the wire is crimped to a ring or fork lug

and is screwed on to the flat

current bar of the terminal block.

The fastening nut in the block

always remains captive in the

hinged plastic carrier and the

carrier is lifted to insert the lugs

and then snapped into position.

The nut can then be fastened to

complete the connection. It can

be operated using a standard

screwdriver too. These terminal

blocks have IP20 (Finger Safe)

protection and do not need any

additional shrouding. In fact, two

lugs can be connected to the

terminal without even sacrificing

the safety of the concerned

block.

The newest solutions for the

packaging industry will be on display

on May 8 - 14, 2014 at interpack 2014

in Dusseldorf

The fastening nut in the block always

remains captive in the hinged plastic

carrier and the carrier is lifted to insert

the lugs and then snapped into position

Energy measurement device

elMeasure has launched Power Duos — an

advanced product that measures both AC and DC

power source of a hybrid power scenario. The

new product offers comprehensive world-class

AC/DC power and dual source energy

measurement and monitoring with communication

option for integration with ElMeasure’s energy

management system that helps to reduce

day-to-day operating costs and to avoid costly

business interruptions. The product combines

state-of-the-art technology with harmonic viewing,

data logging and performance benchmarking.

Power Duos is loaded with features and functions

that can perform multiple tasks that generally

require three or more different products. The key

features include true RMS measurement;

simultaneous sampling of Volts & Amps - AC and

DC and reverse lock option user programmable for

positive energy accumulation. It can be applied in

DC energy management systems; power distribution for

telecommunication tower control room and industrial DC control systems.

The new product

offers comprehensive

world-class AC/DC

power and dual source

energy measurement

and monitoring with

communication option

for integration with

ElMeasure’s energy

management system


> MORE@CLICK ADI03459 | www.AandD24.in > MORE@CLICK ADI03460 | www.AandD24.in

The light curtains consist

of a sender and a receiver

unit which, by exchanging

sequential coded infrared

rays, create a protective field

between them


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Engineering software tool

ePlAn has launched a new version EEC One. Available in 17 languages,

the software supports important international standards and norms for the

global market. The newly integrated dictionary function also ensures

direct access to the EPLAN

dictionary and hence translates

the entire documentation of the

schematics in all possible

languages. Language barriers

are removed and the efficiency

level of the software usage is

increased too. Also, a fixed

value can be specified for the

position of macros with respect

to the predecessor macro. The

deep connection to the EPLAN

Platform is also reflected in the integrated parts selection. The software

directly accesses the EPLAN parts database and transfers parts and their

reference data. Transmission errors can be avoided due to the automated

data transfer and efficiency can be increased at the same time. The

software is compatible with the current EPLAN Platform 2.3 and the

predecessor version 2.2 too.

Available in 17 languages, the software

supports important international standards

and norms for the global market

Test and evaluation kit for real-time ethernet

hilscher gmbh offers a test and evaluation kit for the six most common

real-time-Ethernet systems. The kit

is suitable for development, test

labs, education & end users. It

contains a cifX master PC card,

three NXIO slave test-devices and a

netANALYZER as Ethernet analysis

device with Gigabit-Ethernet

PC-interface. It also contains

Ethernet cables, power supply and

master & slave firmwares for

EtherCAT, EtherNet/IP, Modbus

TCP, POWERLINK (slave only),

PROFINET and Sercos. The

comprehensive documentation

leads the user in a step-by-step

guide through the configuration of the network using SYCON.net. It

explains the measurement of important network parameters using the

netANALYZER which has no influence on the network and analysis

methods supported with graphic output. It also captures all process data

with name resolution & always passive with zero delay.

Stripable control cable series

igus recently introduced CFRIP, which has been added to all control cable

series with PVC jackets and in motor cable families. With the unique CFRIP

principle, chainflex cables can

be stripped quickly and safely in

large lengths without damaging

cores. Similar to a zipper, it

opens by simply pulling on the

CFRIP tearing thread within the

jacket to the desired length. With

it, installers save up to 50% of

the usual required time for

stripping. Apart from that,

specific stripping tools are no

longer required. Along with PVC

control cables chainflex CF5,

tearing thread in the outer jacket

and the shielded version chainflex CF6, tearing thread in the inner jacket

– now the control cable families CF5, CF6, CF130 and CF140 as well as

the complete multi-core motor cable families are equipped with the CFRIP

thread. Around 230 chainflex cable types with integrated CFRIP tool are

currently available. More cable series with integrated CFRIP are in

development.

It contains a cifX master PC card,

three NXIO slave test-devices and a

netANALYZER as Ethernet analysis device

with Gigabit-Ethernet PC-interface

With the unique CFRIP principle,

chainflex cables can be stripped quickly

and safely in large lengths without

damaging cores




Pneumatic rotary lift

SchUnK has added the pneumatic rotary lift unit DRL 20 to its program

for modular high-performance assembly. It

offers a particularly compact unit and allows

highly dynamic and smooth pick & place

operations in confined spaces of the

complex assembly plants, assembling

electronics, medical and consumer goods

with rotating angles of 90° or 180°. Since

the units are positively driven behind the

movement of the vertical cylinder and the

rotary drive by a cam roller, both can be

switched sooner and the cycle time is

considerably shortened. At a minimum

loading and rotation angle of 180°, 75 cycles

per minute can be achieved. To additionally

increase the plant’s productivity and process

reliability, its effector can be directly stopped

over the individual target position. It will go

into standby position, until the feeding or the

deposit unit is ready. At an operating

pressure of 5 bar, it achieves a torque of

2.26 Nm and a lifting force of 245 N.

DRL 20’s effector can

be directly stopped

over the individual

target position


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Light-weight laser profile scanner

Micro-epsilon has introduced a compact,

light-weight laser profile scanner -

scanCONTROL 2600/2900 with

integrated controller enclosed in a 380 g

aluminium housing. While the small

sensor provides a large range of features,

up to 4,000 profiles per second can be

transferred to a PC for further processing.

It also offers a measuring rate up to 640

points per profile. The measuring range

starts at a distance of 53 mm from the

sensor and can be extended up to 390

mm, depending on the sensor model.

Gigabit ethernet interface and

multi-purpose interface for RS422

connections are available for the scanner.

The digital inputs can be used for

synchronising and triggering. An additional output unit can be used to

provide more output signals. It is particularly well suited for applications

that require a low sensor weight, for example, in automotive production

or when sensors are mounted to robot arms.

The scanCONTROL

2600/2900 offers a

measuring rate up to 640

points per profile

Measuring light grid

Pepperl+Fuchs has recently launched the new LGM

Series measuring light grid where the values are

digitally transmitted at extremely fast cycle times,

even with beam crossover activated, using IO-Link,

enabling convenient commissioning and

maintenance from the control level.

Parameterisation and configuration are completed

via a PC. The light grids have an ultra-low profile to

fit into tight spaces. Innovative, tool-free mounting

accessories make installation, alignment and

replacement fast and easy. The IP67 aluminium

housing withstands harsh environmental conditions

even at cold-storage temperatures. It is available

with various resolutions and field heights up

to 3200 mm, permitting large measuring

ranges. Unlike complex products with

single-beam output that evaluate each beam

measuring light grids provide measured

values in millimeters without time-consuming

calculations and set new standards with their compact design,

functionality and unique price/performance ratio.

The LGM light grids

have an ultra-low

profile to fit into

tight spaces

> MORE@CLICK ADI03467 | www.AandD24.in > MORE@CLICK ADI03468 | www.AandD24.in

Managed switches for Ethernet network

Phoenix contact has launched new managed switches of 3000 Series

which support comprehensive IT–compatible functions range and are

reliable and maintenance-friendly and ideal for inexpensive & reliable

ethernet networks. The

comprehensive features of the

switch include easy to fit in

industrial harsh environment such

as narrow design, DIN rail

mountable and extended temp

range up to 75 degrees. The

redundant power supply features

increase the maximum availability

of the switches and LEDs. They

also possess extended ring

redundancy in critical

infrastructure applications. It has

the latest security functions such as 802.11 x radius authentication;

Mac based port security and encrypted management access with

HTTPS. To increase network performance, comprehensive filtering and

prioritising functions can also be configured through static and dynamic

VLAN, flow control, storm control and traffic shaping along with quality

over Service (QoS) with four priority queues.

The redundant power supply features

increase the maximum availability of

the switches and LEDs


Statement about ownership & other particulars about A&D, as required to be

published in the first issue every year after the last day of February

1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001

2. Periodicity of Publication: Bi-monthly

3. Printer’s Name: Kala Jyothi Process Pvt Ltd

Address: S.No. 185, Kondapur, R R District, AP 500 133

4. Publisher’s Name: Shekhar Jitkar

Nationality: Indian

Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001

5. Editor’s Name: Shekhar Jitkar

Nationality: Indian

Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001

6. Names & addresses of individuals who own A&D and partners or shareholders holding

more than 1% of total capital of publish-industry India Pvt Ltd, 302, Sarosh Bhavan, Dr

Ambedkar Road, Camp, Pune 411 001

Details of the shareholders of publish-industry India Pvt Ltd who are holding more than

1% of the paid up equity share capital of the company as on 24-04-2014:

a) publish-industry Verlag GmbH, NymphenburgerStrasse 86, 80636 Munich, Germany

b) Kilian Mueller, NymphenburgerStrasse 86, 80636 Munich, Germany

I, Shekhar Jitkar, hereby declare that all the particulars given above are true to the best of

my knowledge and belief.

Dated: 24th April 2014

Sd/-

SHEKHAR JITKAR

Signature of the Publisher

80 A&D I nd i a | A p r-Ma y 2014

Highlights - (Jun/Jul 2014)

h Igh l Igh t s | compA ny InDex | Impr Int

company IndexName . . . . . . . . . . . . . . . . . . . . . . . . . Page

ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Allegion India . . . . . . . . . . . . . . . . . . . . . . . 18

Analog Devices . . . . . . . . . . . . . . . . . . . . . 64

Ansys Inc . . . . . . . . . . . . . . . . . . . . . . 12, 14

ARC Group . . . . . . . . . . . . . . . . . . . . . . . . 20

Automation Industry Association (AIA) . . . 36, 74

Avadhoot Automation . . . . . . . . . . . . . . . . . 36

Avasarala Technologies . . . . . . . . . . . . . . . . 36

B&R Industrial Automation . . . . . . Cover, 6,7, 77

Baumer . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Bharat Bijlee . . . . . . . . . . . . . . . . . . . . . . . 29

Chanto Air Hydrantics Co Ltd . . . . . . . . . . . . 15

Connectwell Industries . . . . . . . . . . . . . . . 9, 77

Contrinex Automation . . . . . . . . . . . . . . . 1, 77

CST Sensors . . . . . . . . . . . . . . . . . . . . . . . 27

Delta India Electronics . . . . . . . . . . . . . . . . . 31

Deutsche Messe . . . . . . . . . . . . . . . . . . . . . 70

EIMeasure . . . . . . . . . . . . . . . . . . . . . . . . . 77

Emerson Network Power . . . . . . . . . . . . . . . 10

Emerson Process Management . . . . . . . . . . 42

Eplan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Faro Business Technologies . . . . . . . . . . . . . 23

Festo Controls . . . . . . . . . . . . . . . . . . . . . . 41

Galil Motion Control . . . . . . . .Back Inside Cover

HGS Automation . . . . . . . . . . . . . . . . . . . . . . 8

Hilscher India . . . . . . . . . . . . . . . . . . . . 19, 78

HMS Industrial Networks . . . . . . . . . . . . . . . 57

Honeywell . . . . . . . . . . . . . . . . . . . . . . . . . 34

Hummel Connector Systems . . . . . . Back Cover

ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 59

IFM Electronic India . . . . . . . . . . . . . . . . . . . 47

Igus India Pvt Ltd . . . . . . . . . . . . . . . . . . 2, 78

IIITB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . 12

Kubler Automation . . . . . . . . . . . . . . . . . . . 61

Lapp Cables . . . . . . . . . . . . . . . . . . . . 12, 76

MathWorks . . . . . . . . . . . . . . . . . . . . . . . . 10

MentorWise Advisors . . . . . . . . . . . . . . . . . . 36

Messe Frankfurt . . . . . . . . . . . . . . . . . . . . . 67

Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . 5, 79

Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 63

National Instruments . . . . . . . . . . . . . 4, 16, 56

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Okuma . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Omron Automation . . . . . . . . . . . . . . . . . . . . 3

P+F FA Division . . . . . . . . . . . . . . 8,12, 45,79

P+F PA Division . . . . . . . . . . . . . . . . . . 17, 36

Parker Hannifin . . . . . . . . . . . . . . . . . . . . . . 53

Phoenix Contact . . . . . . . . . . . . . . . . . . 55, 79

Pilz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Red Lion . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Reliance Industries . . . . . . . . . . . . . . . . . . . 24

Renu Electronics . . . . . . . . . . . . . . . . . . . . . 39

Rockwell Automation . . . . . . . . . . . . . . . . . . 62

Schneider Electric . . . . . . . . . . . . . . . . . . . . . 8

Schunk Intec India . . . . . . Front Inside Cover, 78

Sesame Motor Corp . . . . . . . . . . . . . . . . . . 65

Siemens PLM . . . . . . . . . . . . . . . . . . . . . . . 8

Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TÜV SÜD Chemie Service . . . . . . . . . . . . . . 48

VDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Vega India Level & Pressure Measurement . . . 11

ImpRInT

Efficient Manufacturing

Automation & Drives

Test & Measurement »Wireless is changing the face of test & measurement equipment at a pace never seen before. due to the increasing need for greater accuracy and higher definition measurement, the tools involved in the test and measurement industry are constantly developing to accommodate technological advancements in the industries they cater to. The upcoming issue gives an insight into the recent advancements made in this field and looks at how beneficial the systems can be to various industries

Fieldbuses & Networks »In the recent years, there has been an increase in focus on application of Fieldbus & networks technology. one of the problems that have impeded the rapid adoption of fieldbus technology has been the lack of standardisation. Several competing alliances were created that all strived to develop an open fieldbus that would establish itself as standard. The result is that today there exist a plethora of standards for open fieldbuses. In the next issue, we take a look at some of the standards and recent developments in this sector.

Pharmaceuticals & Packaging »The pharmaceutical industry has poured millions of dollars into new technologies over the past two decades, but this has had little impact on the high drop-out rate and cost of drug development. The next issue addresses latest developments in automation for this industry vertical, steps toward miniaturisation, and robotics-based strategies. most companies acknowledge packaging and packaging operations as significant components of their supply chains. The next issue will focus on the latest innovations in automation technologies for this sector, RFId, and will present application stories from the world of packaging industry.

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A&d apr may 2014

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