ControlEng MAY2016

Sm
ar
an
uf
hy
tM
www.controleng.com
rin
ig
tu
ac
th
ra
Si
en
pa
ge
21
yo
u
Se
ay
he
em
te
fo
rd
ca
et
ai
ls
od
er
ni
ze
?
Get BIG DATA and BIG SAVINGS...

...with a new Point of View!
HMI/SCADA Software
Point of View is powerful software for developing HMI, SCADA, and
OEE/Dashboard projects for your control system that can be deployed
anywhere. Create informative screens that are easily understood with
detailed graphics, animations, alarms, data trends, and more. With
Point of View you get advanced capability for a very practical price, no
matter how small or large the system.
BIG DATA...
Starting at:
$225 .00
PV-500-DEV
(Development only package)
BIG SAVINGS...
Database Connectivity:
Connect to any SQL database (MS SQL,

MySQL, Sybase, Oracle), or MS Access
or Excel, and ERP/MES systems
(including SAP).
FTP Transfer:
Automatically upload or download les
during runtime to/from remote storage
locations using FTP protocol and exible
scripting functions.
Optimized Trend History:
Three software packages are available in

500, 1000, and 5000 tag count versions:
Designed to load millions of values

from SQL relational databases with
high performance.
Plus:
Complete Package - Development + Runtime

starting at: $495.00 [PV-500]
Powerful scripting including VBScript

System redundancy
Web, Secure Viewer, and Mobile Thin
Client connections
Convenient PDF export
Much, much more...
Development Package - Development Only

starting at: $225.00 [PV-500-DEV]
Runtime Package - Runtime Only
starting at: $345.00 [PV-500-RT]
Get more than you paid for: www.automationdirect.com/point-of-view
Order Today, Ships Today!

* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
1-800-633-0405
input #1 at www.controleng.com/information
the #1 value in automation
DO MORE WITH
YOUR DATA
Introduce real-time industrial data to your cloud-based business

systems with Kepwares industry-leading communications platform.
Kepware Technologies provides a portfolio of software solutions

that connect diverse industrial automation devices and software
applications. Established in 1995 and now distributed in more than
100 countries, Kepware has helped thousands of customers improve
operations and decision making.
Visit us online to learn more about our communications platform
thats enabling the Internet of Things.
Expected change to 2016

base annual salary
MAY 2016
Increase more than 6%
Decrease
ncrease 4% to 6%
Increase
9%
Vol. 63
Number 5
Stay the same
4%
2%
2
31%
54%
ncrease 1% to 3%
Increase
18
Features
18 Control Engineering
Salary and Career Survey
COVER: Control Engineering Salary Survey graphic, upper

right, main cover image is courtesy of NexDefense; inset,
left is from Honeywell Process Solutions. See research
results, advice, and learn of the need for a succession plan.
Cover story: Control Engineering research shows salary increases,

salary benchmarks by various parameters, job satisfaction, and an
increase in the importance of of financial compensation.
24 Manufacturing organizations need a succession plan.
25 Engineering career advice from survey respondents
26 Automation products improve

with customer feedback
As customers give suppliers valuable product feedback, suppliers
will consider many factors that can result in new features.
29 Smart manufacturing is not a thing;

its a convergence of things
Smart manufacturing converges smart business processes and smart
operational processes, smart equipment, and more.
32 Process historians can be an integral

part of the IIoT
34
Process historians can help with distributed, cloud-based enterprises

and integrate with the Industrial Internet of Things (IIoT).
34 Optimizing remote collaboration,

monitoring at process plants
Mobile solutions allow plant supervisors and managers to better
analyze and collaborate on problems and abnormal situations.
36 Modern control valves offer

communications, diagnostics
New pneumatic automation can increase machine performance and reliability, reducing compressed air costs by nearly half, in one example.
38 Partial stroke valve testing

New partial stroke testing advances are available in a hybrid approach,
explained Richard Harvey, in Control Engineering Europe.
41 Hannover Messe Recap

Recap of events and developments at the 2016 show in Germany
57 Digital Edition Exclusive

How secure is the Internet of Things?; Getting ahead of the IIoT cyber
security curve; More on automation integration savings.
MAY 2016
CONTROL ENGINEERING
36
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 63, No. 5, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak
Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/
Co-Founder. CONTROL ENGINEERING copyright 2016 by CFE Media, LLC. All rights reserved.
CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license.
Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation
records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL
60523. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to
CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses
to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@
cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $150/yr;
Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery
$325/yr. Except for special issues where price changes are indicated, single copies are
available for $30.00 US and $35.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the
USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for
any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
www.controleng.com
Maximize Productivity of
Sensitive Remote Assets
In order to succeed in a highly competitive industry, you need every edge you can get. You can improve
productivity with intelligent analysis of real-time data from your remote assets, but you need to make sure
that you dont also expose those assets to unauthorized access. With industrial secure routers like
Moxas EDR-810, your operations are protected while remote assets collect, share, and act on data.
Its easier than you think. Find out more at www.moxa.com.
EDR-810
Industrial Secure Router
Ethernet Switches Wireless AP/Bridge/Clients Cellular Gateways

Secure Routers Gateways and Protocol Converters Media Converters
Serial Device Servers Multiport Serial Boards IP Cameras
Video Servers Remote I/O and Controllers Embedded Computing
linkedin.com/company/moxa
Moxa Inc.
@moxainc
Tel: 1-888-669-2872
youtube.com/moxavideo
usa@moxa.com
facebook.com/moxainc
www.moxa.com
Safeguard Your Facility

with Layers of Protection
Now Get Moore Industries Alarm Trips

with Intrinsically-Safe Field Connections.
Moore Industries family of rugged and reliable alarm
trips now includes the SPA2IS for process areas requiring
intrinsically-safe methods of protection. The new SPA2IS
alarm trip lets you directly connect temperature sensors
and transmitters in Class I, Div1 or Zone 0,1 hazardous
locations without having to use intrinsically-safe barriers,
cutting wiring and maintenance expenses.
Add a layer of protection to keep your facility safe and
reduce costs with the SPA2IS with intrinsically-safe eld
connections.
Demand Moore Reliability
To learn more about the SPA2IS and Moore Industries family of

Programmable Alarm Trips, call 800-999-2900 or visit:
www.miinet.com/alarmtrips
MAY 2016
Original
dataset
Random
Random
Random
Record set 1
Vol. 63
Number 5
Inside Process
Appears after page 46; If not, see the Digital Edition:
www.controleng.com/DigitalEdition
Record set 2
T
Training
dataset
T
Test
dataset
V
Validation
dataset
Record set 4
Record set 1
Record set 2
Record set 3
Record set 5
Record set 4
Record set 7
Record set 5
Record set 6
Record set 6
Record set 8
Record set 6
...
Record set 12
Record set 10
Record set 9
Record set n
Record set 17
Record set 14
Record set 11
...
...
...
Record set n
Record set n-1
Record set n-2
Record set 3
P1
P1 Neural networks in process control:

Neutral network training, implementation
Neural network technology has been applied in a number of
fields with great success. Part 2 of this 2-part series covers preparing the dataset for training, neural network model training and
validation, implementing a neural network model on a control
platform, and human-machine interface (HMI) requirements.
P8 Developing high-performance HMIs:

Evolution, improved usability
This two-part series examines the development of high-performance human-machine interface (HMI) methodology. Part 1 covers HMI evolution, security, improving usability, and consistent
use of color.
Departments
8 Think Again
Advice on integrating legacy technology with IIoT
P8
Products
61 Safety diagnostics system;

Coriolis transmitter has Ethernet
connectivity (left); Cartesian robot;
Software upgrade for modeling
and simulation platform (bottom);
process viscosity analyzer
10 Apps for Engineers

Mechanical apps
14 Control Engineering International

Robots are ready to populate smart factories.
64 Back to Basics
Control system power and grounding forensic exam
aids reliability.
62
Brushless dc motor (left)

has sensors that report rotor
location; Temperature control
system series
for heating, chilling cycles;
linear motion platform
News
16
Advanced robotics help manufacturing.

Software construction guidelines released
Automation company elects president, CEO.
Online headlnes
17
3D holographs for advanced manufacturing

Motor and drive company names CEO.
www.controleng.com
CONTROL ENGINEERING
MAY 2016
| 5
More resources posted daily at:
MAY
Trending
www.controleng.com
New Products
Control Systems
Process Manufacturing Discrete Manufacturing
Ensuring network
cyber security
Theres a lot more to read
online. Go to
www.controleng.com/news
to read Control Engineerings
exclusive Web content.
Physical security meets OT
Companies to create smart
microgrid using Internet of Energy platform
Standards for industrial cloud interface being developed
Robots usage growing on production line, but humans still valuable.
System Integration
Networking & Security
Info Management
Education & Training
Webcasts for credit

Control Engineerings
webcasts are always
available on demand at any time. If
you need additional
continuing education credits, you can
meet your requirements at
www.controleng.com/webcasts.
Webcasts
Next-generation Industrial HMIs

Industrial Internet of Things Webcast
Series 2016, Part One: Effective Change
Management
Changing ROI for Industrial Robotics
Information Integration and IIoT.
NEWSLETTER: IIoT REPORT
Use IIoT to improve

operations
IIoTs power found in controllers, HMIs
Data analysis: a key requirement for IIoT
Define maintenance data value to gain
IIoT benefits.
Keep up with the latest industry news
by subscribing to Control Engineerings
14 newsletters at
www.controleng.com/newsletters
2016 Cybersecurity
Study: Six key findings
Now available, latest research: See
six key findings highlighted in this
Control Engineering research and
download the full report.
Point, click, watch

VIDEO: Hannover Messe
Online exclusive: See video from Hannover
Messe in Hannover, Germany.
www.controleng.com/videos
MAY 2016
CONTROL ENGINEERING
Oil & Gas Engineering

April issue
Oil & Gas Engineering provides industryspecific solutions designed to maximize
uptime and increase
productivity through
the use of industry
best practices and
new innovations,
increase efficiency
from the wellhead to
the refinery by implementing automation
and monitoring strategies, and maintain
and improve safety for workers and the
work environment. Read the digital edition at www.oilandgaseng.com.
Digital Edition
The tablet and digital
editions of this publication have unique
content for digital
subscribers. This month
has digital exclusives
on: Internet of Things
(IoT) security; Get
ahead of the Industrial IoT security curve;
More automation
integration savings.
www.controleng.com
Reliable Detection
For Your Application
You cant afford not to know. See it all at thinkallied.com/sensors
1.800.433.5700
Allied Electronics, Inc 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
THINK AGAIN IIoT

1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
630-571-4070, Fax 630-214-4504
Advice on integrating
legacy technology with IIoT
Industrial Internet of Things (IIoT) methods can help increase quality,
throughput, and cybersecurity, while decreasing unplanned downtime,
said speakers at the Industrial IoT USA conference in Chicago.
To take advantage of increased
communications needed for Industrial

Internet of Things (IIoT) initiatives, legacy
equipment has to deliver data to help eliminate unplanned downtime and improve
quality and efficiencies, said participants at
the Industrial Internet of Things USA conference in Chicago in April. Representatives from Dell, Digital Manufacturing and
Design Innovation Institute (DMDII), Monsanto, and OPC Foundation were among
those offering advice at the conference,
organized by Qatalyst Global. IIoT increase
throughput and enable data-rich applications, such as predictive maintenance.
Thomas Burke, president and executive
director, OPC Foundation, served as conference chairman and a panelist, and said greater collaboration among industry vendors and
organizations enables faster IIoT benefits. This
includes more connectivity, more easily and
securely, with legacy systems, Burke said.
ExxonMobil Research and Engineerings
chief engineer, process control, Don Bartusiak, moderated the opening panel discussion and said while process control systems
have had a network of things for 35 years,
its astonishing to see the progress of Internet communications compared to process control networks. Remote monitoring
capabilities have been increasing, and Bartusiak expects mobile operators to have read
capabilities, although reliability and security
are major concerns. Mobile write access is a
higher-risk capability at this time, Bartusiak
suggested, somewhat akin to flying a plane
from outside the cockpit.
To get value more quickly from IIoT technologies, DMDII made a request for propos-
MORE
als for an IIoT retrofit kit, said Jacob Goodwin,

director, membership engagement, DMDII, a
public/private partnership of industry and academia to deliver innovation to manufacturing.
Wider use of standards by technology providers would improve data flow, said Atif Khan,
senior automation manager, smart fields,
Monsanto. Integration of OPC Unified Architecture (OPC UA) helps data flow among disparate systems, speeding decisions on quality.
An IIoT retrofit kit would help, he said.
Deciphering IIoT benefits
Cooperation of information technology

(IT) and operational technology (OT) teams
can help increase information flow, said
Christine Frank, director of industrial strategic partnerships, SME (Industrial) Global,
Dell, and a keynote speaker. Frank said IIoT
technologies connect the plant floor to the
enterprise to analyze, optimize, and increase
performance of industrial equipment and
improve end-to-end business processes.
IIoT can help with competition, regulations,
resource constraints, changing customer
demands, and an aging workforce.
For predictive maintenance (PdM), IIoT
technologies help address talent gaps, budget
pressures, and a greater need to better manage assets and energy, Frank said. Applying
PdM through gateways can create legacy connections, Frank said. She told Control Engineering that a connected worker should think
again about how to be more effective and
safer in plant-floor interactions.
IIoT technologies are for those who want
to compete and stay relevant, Frank said, and
physical and cybersecurity are imperative. IT
and OT convergence can help, but it isnt going
to happen overnight. ce
MAY 2016
CONTROL ENGINEERING
Mark T. Hoske, Content Manager

847-830-3215, MHoske@CFEMedia.com
Jack Smith, Content Manager
630-907-1622, JSmith@CFEMedia.com
Emily Guenther, Associate Content Manager
630-571-4070 x2220, eguenther@cfemedia.com
Amanda Pelliccione, Director of Research
631-320-0655, APelliccione@CFEMedia.com
Joy Chang, Digital Project Manager
630-571-4070 x2225, JChang@CFEMedia.com
Chris Vavra, Production Editor
630-571-4070 x2219, CVavra@CFEMedia.com
Contributing Content Specialists

Frank J. Bartos, P.E., braunbart@sbcglobal.net
Peter Welander, PWelander@CFEMedia.com
Vance VanDoren, Ph.D., P.E., controleng@msn.com
Suzanne Gill, Control Engineering Europe
suzanne.gill@imlgroup.co.uk
Ekaterina Kosareva, Control Engineering Russia
ekaterina.kosareva@fsmedia.ru
Wojciech Stasiak, Control Engineering Poland
wojciech.stasiak@trademedia.us
Luk Smelk, Control Engineering Czech Republic
lukas.smelik@trademedia.us
Aileen Jin, Control Engineering China
aileenjin@cechina.cn
Publication Services
Jim Langhenry, Co-Founder/Publisher, CFE Media
630-571-4070, x2203; JLanghenry@CFEMedia.com
Steve Rourke, Co-Founder, CFE Media
630-571-4070, x2204, SRourke@CFEMedia.com
Trudy Kelly, Executive Assistant,
630-571-4070, x2205, TKelly@CFEMedia.com
Elena Moeller-Younger, Marketing Manager
773-815-3795, EMYounger@CFEMedia.com
Kristen Nimmo, Marketing Manager
630-571-4070, x2215, KNimmo@CFEMedia.com
Brian Gross, Marketing Consultant, Global SI Database
630-571-4070, x2217, BGross@CFEMedia.com
Michael Smith, Creative Director
630-779-8910, MSmith@CFEMedia.com
Paul Brouch, Director of Operations
630-571-4070, x2208, PBrouch@CFEMedia.com
Michael Rotz, Print Production Manager
717-766-0211 x4207, Fax: 717-506-7238
mike.rotz@frycomm.com
Maria Bartell, Account Director
Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
Rick Ellis, Audience Management Director
303-246-1250, REllis@CFEMedia.com
Letters to the editor: Please e-mail us your opinions to
MHoske@CFEMedia.com or fax us at 630-214-4504.
Letters should include name, company, and address,
and may be edited for space and clarity.
Information: For a Media Kit or Editorial Calendar,
email Trudy Kelly at TKelly@CFEMedia.com.
Reprints
For custom reprints or electronic usage, contact:
Brett Petillo, Wrights Media
281-419-5725, bpetillo@wrightsmedia.com
Publication Sales
Patrick Lynch, ContentStream, Director of Content Marketing Solutions
630-571-4070 x2210
PLynch@CFEMedia.com
Bailey Rice, AR, IL, IN, IA, KS, KY, LA, MN, MO, MS, NE, ND, OK, OH, SD, TX, WI,
Central Canada
630-571-4070 x2206
BRice@CFEMedia.com
Iris Seibert, AK, AZ, CA, CO, HI, ID, MT, NV, NM, OR, UT, WA, WY,
Western Canada
ADVICE
GO ONLINE
With this article at www.controleng.com, see IIoT
conference details, PdM tips, and new IIoT pages.
Content Specialists/Editorial
858-270-3753
ISeibert@CFEMedia.com
Julie Timbol, CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WV, DC,
Eastern Canada
Mark T. Hoske, Content Manager

MHoske@CFEMedia.com
978-929-9495
JTimbol@CFEMedia.com
Maggie Hatcher, AL, FL, GA, MI, TN, classified, product mart, media
showcase
630-571-4070, x2221
MHatcher@CFEMedia.com
Stuart Smith, International
www.controleng.com
Tel. +44 208 464 5577
stuart.smith@ssm.co.uk
Wireless Mesh Network.

Wired Reliability.
Every Node Can Run on Batteries for >10 Years at >99.999% Reliability
The Dust Networks LTC 5800 and LTP 5900 product families from Linear Technology are embedded wireless sensor
networks (WSN) that deliver unmatched ultralow power operation and superior reliability. This ensures flexibility in
placing sensors exactly where needed, with low cost peel and stick installations. The highly integrated SmartMesh
LTC5800 (system-on-chip) and LTP5900 (PCB module) families are the industrys lowest power IEEE 802.15.4e compliant
wireless sensor networking products.
Features
Highly Integrated LTC5800 and

LTP5900 Families
s2OUTING.ODES#ONSUME<50A
Average Current
s>99.999% Reliability Even in the
Most Challenging RF Environments
s#OMPLETE7IRELESS-ESH3OLUTIONn.O
Network Stack Development Required
s.ETWORK-ANAGEMENTAND.)34
Certified Security Capabilities
sTwo Standards-Compliant Families:
SmartMesh IP (6LoWPAN) and
SmartMesh WirelessHART (IEC62591)
32kHz
20MHz
www.linear.com/dust
1-800-4-LINEAR
LTC5800
Flash
512KB
Info & Starter Kits
SRAM
72KB
AES
Crypto
SmartMesh
Networking
Software
MAC
Engine
ARM
Cortex-M3
CLI
UART
(2-pin)
API
UART
(6-pin)
Temp
Sensor
TX
PA
802.15.4e
Transceiver
ICX
Analog
Inputs
Digital
I/O
LTP5900/1/2
(PCB)
www.linear.com/starterkits
, LT, LTC, LTM, LTP, Linear Technology, the Linear logo, the
Dust Networks logo and SmartMesh are registered trademarks of
Linear Technology Corporation. All other trademarks are the
property of their respective owners.
APPS FOR ENGINEERS data collection

www.controleng.com/appsforengineers
Mobile apps for mechanical applications

Mechanical mobile applications have potential to help engineers do their jobs better.
CFE Medias Apps for Engineers is an interactive directory of engineering-related applications for Apple iOS and Android operating systems from various companies. Apps are
organized by category, company, and type. These are listed in the app as of May 2016.
Coverter-Universal Conversions
Friction Calculator
iOS 6.0+
iOS 4.0+
Cost: Free
Company: Trelleborg Sealing Solutions
Website: www.tss.trelleborg.com
Cost: Free
Company: T2 Content Works
Website: www.magnaplate.com
Trelleborgs Unit and Hardness Converter helps convert

frequently used units and currencies. It includes a Hardness
Converter based on ISO and ASTM Standards to convert
between popular hardness scales for various material types.
Based on General Magnaplates popular friction calculation

tool, this app provides dynamic as well as static coefficients
of friction (COF) for many pairings of regularly used materials
and engineered coatings.
NI cDAQ-9191 Data Display
TurboTool
iOS 5.0+, Android 2.2+
iOS 6.0+, Android 2.3+
Cost: Free
Company: National Instruments
Website: www.ni.com
Cost: Free
Company: Danfoss
Website: www.airconditioning.danfoss.com
The NI cDAQ-9191 Data Display enables wireless voltage

measurements. Choose a simulated device to evaluate and
configure the number of samples, sampling rate, and channels to acquire.
The TurboTool App makes it easy for field service technicians to troubleshoot Danfoss Turbocor compressor issues
on site. Users can utilize this app to identify symptoms, the
possible causes, and find the required actions for a solution.
Half Page Horizontal Non-Bleed ad; 7 x 4.875
Connect
Automagically.
The New Experion PKS Orion, coming

soon to a control room near you. Also, visit
us at Honeywell Users Group Americas.
www.honeywellusersgroup.com
For more information, please visit

2016 Honeywell International Inc. All rights reserved.
www.honeywellprocess.com/experion
Learn about the latest engineering

trends and technologies.
Check out our Control Engineering
webcasts on topics like:

thernet (with 2015 research)

E
lloT
HMI
Cyber security for industrial
automation
System Integration case studies
lloT, Industry 4.0
and more
Professional Development Hours
are available!
www.controleng.com/webcasts
Be Sure the Hardware You Add

Smart Factory
Transportation
Test & Measurement
Microsoft Azure
See the Full Line of Industrial Automation Products at Buy.Advantech.com
Automotive Manufacturing
Predictive Maintenance
Vision Systems for Packaging
Vehicle Body Control Module

Test System checks switches
and actuation accuracies.
Automation PCs predict

device maintenance before
failure, beyond simple remote
monitoring.
Providing high-speed image

acquisition and analysis on
fast-moving production lines.
1-888-576-9668 Buy.Advantech.com
We Manufacture it > You Click it > We Ship it
See
Application
Stories
Now is Right for You Tomorrow

Environmental and Facility
Oil and Gas
Supply Chain & Logistics
See More Stories at Buy.Advantech.com/go/ApStory
Visual Factory Signage Display
Displaying critical information

in a reliable system, in real-time
and in harsh conditions.
Improving Wind Power Telematics to Improve Supply Chain
Distributed management and

reliable connectivity to control
and monitor wind systems.
Mobile device uplink to backend

systems enables efficiency to
reduce operating costs.
Visit: Buy.Advantech.com | Chat Online | Call: 1-888-576-9668
CONTROL ENGINEERING international
Robots are ready to populate

smart factories
Industrie 4.0 and the smart factories being built are heavily influencing robots that are being
developed in the Czech Republic, which could have major changes on the labor market, according
to Control Engineering Czech Republic.
MORE
ADVICE
KEY CONCEPTS
Industrial robots being made today
are influenced by smart factories and
Industrie 4.0.
In Europe, smart industrial robots
are being used more and more within
Industrie 4.0 cyber systems.
Advanced manufacturing needs
automation to increase.
GO ONLINE
www.controleng.com/international
www.controleng.com/robotics
CONSIDER THIS
What additional impact will smart
factories and Industrie 4.0 have on the
labor market in Europe?
Is it better to have a competitive
smart factory using robotics and
Industrie 4.0 or an uncompetitive
factory that goes out of business and
employs no one?
Robots use is growing rapidly, and

robots are smarter and more integrated. Branislav Lacko, a member of the Czech-Moravian
Automation Association, said, We can expect
an exponential growth of robotics in the coming weeks and months, in his opening speech
at the Robotization and Automation Trends
2016 conference. He has good reason to be
optimistic. According to the International Federation of Robotics (IFR), there are 1.7 million
industrial robots installed in todays factories
with 230,000 installed in the last year alone
and 15% annual growth expected. As more
industrial robots are being installed, theyre
also getting smarter.
Robots in the smart factory
In Europe, there is a noticeable trend towards

using smart industrial robots within Industrie
4.0 cyber systems. Many new robots today are
created with the purpose of working side-byside with humans. Collaborative robots on display at the conference are one way Industrie 4.0
is being implemented. Other highlights included
robots manufacturing Rolex watches with precise movements.
A Mitsubishi robot is demonstrated at the Robotization and Automation

Trends 2016 conference. Courtesy: Luk Smelk, managing director, Control
Engineering Czech Republic
14
MAY 2016
CONTROL ENGINEERING
High-quality robots that can work alongside

humans as well as make sophisticated items are
needed to make smart factories and Industrie
4.0 work. However, beyond manufacturers, system integrators are needed to help the elements
of future smart factories work.
Miroslav Rumpel from Elcom a.s., which is
aiming to bridge the gap between various vendors, said, Future-proof and original integration of the best available automation is the key
for manufacturings future.
Beyond manufacturers, system

integrators can help the elements
of future smart factories work.

Cost of robot labor vs. humans
Another highlight of the conference was a

presentation by Tom Posekan, from koda
Auto, a Czech car manufacturer, who described
the methods for planning robotic manufacturing. While robotic expansion has social and
economic impacts, Posekan said wider use of
robotics reflects the evolving structure in a society where no advanced manufacturing plant can
succeed without increasing the level of automation. Despite the impacts in the employment
area, comparing the hourly rate calculation for
robot operation versus hourly costs per employee shows a vast difference. While a robot will
take about $6 per hour from the budget, human
labor would cost $14 per hour for the same
amount of work, proving that the industry in the
future will undoubtedly rely on industrial robots.
The advantages of automated workplaces start
to overshadow the trade unions voices, even as
smart factories and Industrie 4.0 become more
prevalent in Europes economy. ce
Luk Smelk is managing director of Control
Engineering Czech Republic. Edited by Chris
Vavra, production editor, CFE Media, Control
Engineering, cvavra@cfemedia.com.
www.controleng.com
A NEW ERA OF SAFETY.
Since the invention of the light curtain, SICK has spent more than half a century developing
pioneering innovations for a safer industrial world. The market leader for safety technology is now
once again entering a whole new age with a new generation of safety laser scanners, light
curtains, switches, and encoders: microScan3, deTec4 Prime, STR1, and DFS60S Pro. Whatever
angle you approach industrial safety from, there are common aims: to set new standards for safety
and productivity and to enable customers to implement pioneering solution concepts their way.
We think thats intelligent. www.sickusa.com
INDUSTRY NEWS and events
Impact, innovate, integrate: Advanced

robotics help manufacturing industries
Ways to prevent the decline of manufacturing include greater use of digital
manufacturing and advanced robotics,
attracting more students to engineering, and creating greater flexibility and
innovation. This was among the advice
presented from U.S. and Italian manufacturing experts at the i3 Forum in Chicago
in April.
Challenges, robotics
The manufacturing sector is facing

many challenges, although the future is
bright as advanced technologies are now
maturing with the Internet of Things
(IoT), virtual reality, robotics, etc. Industry leaders highlighted challenges including the lack of young, skilled workers
in the industry and the need to manufacture quality products faster and at a
lower cost. Innovators highlighted what
needs to happen to prevent the decline of
manufacturing, including digital manufacturing, being open to adopting new
technologies, attracting more skilled people to engineering schools; and increasing flexibility and market innovation.
A glaring challenge is the lack of

young, skilled workers in industry, and
automation is picking up the slack in production lines, said industry leaders.
We need to solve common problems
with uncommon solutions, David Corsini, founder of Telerobot Labs said.
The acceptance of robots has been
a big deal in the industry in addition to
decreasing capital costs and easier programming. With the difficulty of finding
workers, robots cant be built fast enough.
The ability for robots and humans to
work collaboratively is vital to faster
operations and abundant innovation.
Humans are underrated. They have
an eccentric vision, Corsini said.
Innovators are very optimistic and
pushing for incorporating more industrial robotics within additional industrial applications. Although there is a fear
that robotics takes away jobs, this is not
the case. Robot benefits include increased
production without compromising product quality; flexible training; answering the decreased availability of skilled
workers; and safer solutions for hostile
Automation company elects president, CEO
ockwell Automations board of directors

has elected Blake D. Moret, a 30-year
veteran of the company, as president
and chief executive officer (CEO), effective
July 1, 2016. At that time Keith D. Nosbusch,
65, who has been president and CEO since
Rockwell Automation has elected

Blake D. Moret (left), a 30-year veteran of
the company and a senior vice president,
to be the new president and chief executive officer (CEO) effective July 1, 2016.
He will be taking over for Keith D. Nosbusch (right), who has served as president and CEO for the company since
2004. Courtesy: Rockwell Automation
16
MAY 2016
CONTROL ENGINEERING
2004, will transition from those roles while

continuing as chairman of the board. Moret,
53, is currently senior vice president of the
companys control products and solutions
segment.
Moret has 30 years of experience in
sales and business management roles in
product, services, and solutions businesses
across Rockwell Automation. He began
his career with the company in 1985 as a
sales trainee. He has subsequently served
in senior positions across the organization, including international assignments in
Europe and Canada. In 2011, he was named
senior vice president of control products
and solutions, one of the companys two
business segments. Moret is a graduate of
Georgia Institute of Technology, where he
earned a bachelors degree in mechanical
engineering. He has served as chair of the
board of the Manufacturing Institute of the
National Association of Manufacturers.
Edited from a Rockwell Automation press
release by CFE Media.
environments. Another challenge is to

maintain product quality, and increase
production and at a low cost.
Marc Allen, president of Boeing International, capitalized on the fact that
robots do not motivate, humans do. We
need to let robots take over and solve the
problems that are out there now, while
humans continue to innovate and move
the industry forward, according to Allen.
Emily Guenther, associate content
manager, CFE Media, Control Engineering, eguenther@cfemedia.com.
Software construction
guidelines released
he PLCopen Coding Guidelines version 1.0 has been released and is

available for download. Version 1.0
contains 63 rules for software programming, which is spread over different
sections such as naming rules, comment
rules, coding practice, languages, and
vendor specific IEC 61131-3 extensions.
These rules are designed to train users
and provide a basis for universities to
help them teach IEC 61131-3 programming
more efficiently.
Software today often absorbs half of
the initial project costs and between 40%
and 80% deals with maintenance over the
life cycle costs of the software. In order
to deal with the complexity of larger programs, modern software development processes supporting a structured approach
and creating re-usable code are needed.
Coding efficiency needs to be increased
via re-use of pre-defined functionalities
and to help to better understand the program over the lifecycle.
Since the release of the first documents, further work was done on creating
PLCopen-compliant function block libraries and structuring and decomposition via
sequential function charts (SFCs).
More at www.controleng.com
See events, upper right.
Top 5 Control Engineering articles
Manufacturing index rebounds
System integrators conference
Constraining robot growth in China
Support-focused enterprise controls.
www.controleng.com
Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news
3-D holographs for advanced manufacturing applications
Work is underway on software that

aims to use hologram technology and
Lego-inspired assembly to help manufacture some of the worlds most complex
machines. The Australian arm of global defense and security company Saab has
partnered with Microsoft to build a range
of training, education, and other complex
3-D holographic applications. Worn as
goggles by users, the Microsoft HoloLens
Platform is the first fully untethered, holographic computer, enabling interaction
with high definition holograms.
Saab Australia Head of Training and
Simulation Inger Lawes said the company
had identified three initial markets: its traditional defense and security market, the
enterprise market, large corporations wanting bespoke applications to address a specific need, and internal applications for the
companys own development.
We want to stay within our business
of defense and security, but we also want
to explore applied markets such as using

HoloLens to support sophisticated manufacturing, he said. Most design work is
done on a computer and is called modelbased design. What we want to do is support model-based assembly where the
models that are designed on a computer
are represented holographically.
Lawes said the holographic images are

projected onto the goggles optical lens and
appear in the field of vision about a meter
from the users eye.
Edited from a Lead South Australia news story by Chris Vavra, production
editor, CFE Media, Control Engineering,
cvavra@cfemedia.com.
Motor and drive

company names CEO
askawa America Inc. (YAI) named

Mike Knapek, president and chief
operations officer (COO) of the Drives
and Motion Division, to the position of CEO.
Knapek takes over for Masahiro Ogawa,
who takes on the role of corporate vice
president and general manager of Yaskawas global robotics business in Japan.
As CEO, Knapek will lead the Drives and
Motion and Motoman Robotics Divisions of
Yaskawa America Inc. He will continue to
serve as president and COO of the Drives
and Motion Division. In August 2015, Knapek became corporate vice president of
Yaskawa Electric Corp. in Japan.
Knapek began with Magnetek Inc. in
1986. After Yaskawa acquired the Magneteks drives division, he took on leadership roles in several product areas for
Yaskawa and later became responsible
for the drives business in North and South
America. Knapek became president and
chief operations officer (COO) of Yaskawa
America Inc. in March 2011.
Safety is not an option.

ACS880 Industrial Drives
Yaskawa America Inc.

named Mike Knapek as its
next CEO. Courtesy: Yaskawa
America Inc.
CONTROL ENGINEERING
MAY 2016
| 17
2016
COVER STORY
CAREER UPDATE
Control Engineering
Salary and career survey

Control Engineering research shows nearly a 5% increase in salaries among respondents to an
average of $94,747; analysis of salaries by years with employer shows upward salary pressure for
engineering new hires. Respondents continue to indicate they like their jobs, by more than 80%
this year, but financial compensation is becoming more important, as the economy is seen as the
biggest threat by far to manufacturing today.
S
Main cover image across the
top courtesy: NexDefense
Above: Honeywell Process
Solutions
MORE
ADVICE
KEY CONCEPTS
Many engineers like their jobs, and
financial compensation is now about
as important as technical challenge
for job satisfaction.
Breaking out salaries by variables
allows benchmarking.
The economy ranks as the biggest
threat to manufacturing business
today.
GO ONLINE
If reading the digital edition, click
through the headline to get to the
online version with more analysis and
graphics, or search on the headline
atop www.controleng.com.
See write-in advice from survey
respondents in this issue on page 8
with more online in the full report,
available for downloading at
www.controleng.com/CE-Research.
CONSIDER THIS
Whats your plan for demonstrating
and documenting your value this year?
18
MAY 2016
alary for respondents to the 2016 Control Engineering Salary and Career Survey increased about 5% to $94,747,
compared to an average of $90,367 for
respondents last year. This year, data
analyses include tables showing compensation by
seven criteria, allowing benchmarking; the tables
also show upward salary pressure to get younger
engineers in the door. More than 80% were satisfied with their jobs, and 44% love going to work
every day, and while technical challenge remains
the top factor contributing to job satisfaction, it
was a statistical tie (39% and 37%) with financial
compensation, which jumped from 28% last year.
Among key issues, the economy is perceived as
the biggest threat to manufacturing business, and,
perhaps most disturbingly, 12% of respondents said
no cybersecurity program was in place at their site.
(See a cybersecurity research report from Control
Engineering at www.controleng.com/CE-Research.)
The average base annual salary for the 2016 set

of respondents to this years Control Engineering
Salary and Career Survey was $94,747, up slightly
compared to that of respondents to the 2015 survey, when the average totaled $90,367. In 2016,
67% expect a salary increase. Among respondents,
54% expect a 1% to 3% increase, 9% expect a sal-

base annual salary

non-salary compensation
Decrease
ncrease 4% to 6%
Increase
9%
Salary increases
ncrease
Increase
% to 3%
1%
31%
ncrease 1% to 3%
Increase
Figure 1: Just 9% of respondents expect a salary

increase of 4% to 6% in 2016; 54% expect a 1% to
3% increase, and 31% dont expect a change. All
figures courtesy: Control Engineering 2016 Salary
and Career Survey research report
5% 4%
2%
2
54%
CONTROL ENGINEERING
See related articles on engineering advice and

succession planning. More information and graphics appear with the online version of this article;
search on the headline atop www.controleng.com or,
if reading the digital edition, click on the headline.
Thank you to survey respondents; with 222
responding between March 7 and March 18 via
Web-based survey, the margin of error is plus or
minus 6.6% at a 95% confidence level. A gift card
incentive was used.
Increase 4% to 6%
Stay the same
4%
Online, methods
Decrease
16%
18%
57%
Stay the same
Figure 2: Among respondents, 57% expect about

the same non-salary compensation in 2016.
www.controleng.com
ary increase of 4% to 6%, and just 4% expect a

more than 6% increase. About 31% of respondents
expected salaries to stay the same (compared 25%
last year), and only 2% expect a pay cut in 2016
(see Figure 1).
Year to year, those answering the survey differ; this years demographic information is provided later.
The non-salary compensation average among
the 74% of respondents getting a bonus was $13,290
in 2016, and among all respondents, the average is
$9,780. In 2016, 27% of respondents expect more
nonsalary compensation, 16% expect less, and 57%
expect the same (see Figures 2 and 3).
A larger majority of survey takers, 80%, said
bonuses are tied to company profits compared to
61% last year. Among criteria, also up significantly was personal performance, 59% compared to
48%, and safety at 31% compared to 21%. Other
criteria were product profitability at 29%, quality 26%, plant or line productivity 25%, reducing plant costs 21%, uptime/downtime 18%, and
energy efficiencies at 12% (see Figure 4).
NEW: Salary benchmarks
Responding to reader feedback, tables were

added to show salaries by age, education, years
with employer and industry, job title and function,
and number supervised, allowing benchmarking
by taking an average of each that most closely fits
your situation.
TO SEE THE TOTALS for each benchmark
area, with higher granularity by age, sample
sizes, with additional trends, graphics, and
analysis, download the salary survey report
at www.controleng.com/CE-research.
Salary averages are $58,376 under age 30, with

an average nonsalary compensation of $7,211.
Salary average increases above $86,000 for
those in the 30s, nearly $97,000 for those in the
40s, about $95,000 for those in the 50s, increasing
to over $106,000 in the 60s, and above $105,000
for 70 or older, which had the highest nonsalary
compensation, but sample size was very small, just
two at 70 and older.
More education generally resulted in more salary, except for those only with the high school diploma, where the sample size was very small, only four.
Number of years with current employer showed
salary pressure to attract new employees; those
onboard fewer than 5 years averaged more in salary
than two other 5-year tenure periods.
Number of years in current industry increased
steadily up to 20 to 24 and then dipped a bit for
www.controleng.com
Compensation
Compensation statistics
Average salary of 212 respondents
$94,747
Minimum salary
$22,800
Maximum salary
$230,000
Non-salary compensation
Average (all respondents)
$9,780
Percentage of respondents that receive bonus
74%
Average (respondents that receive bonus)
$13,290
Figure 3: Average salary is $94,747, and average non-salary compensation is

$9,780 among all respondents, with $13,290 among the 74% of respondents
getting any extra.
Criteria for non-salary compensation

Company profitability
80%
Personal performance
59%
Safety metrics
31%
Product profitability
29%
Quality metrics
26%
Plant or line productivity
25%
Reducing plant costs
21%
Uptime/downtime
18%
Energy efficiencies
Other
12%
4%
the next 10 years, continuing the upward trend

35 years and up.
Best three titles to have for salary are project
manager, engineering manager, and vice president.
Worst three are manufacturing engineer, plant engineer, and owner (although dont feel sorry for the
owners; they had the third largest average nonsalary
compensation at $25,000). Controls engineer came
in about the middle of the pack, at 12 among 20.
Nonsystem integration consulting had the
lowest among primary job functions, just under
$73,000; system integration was more than
$92,000; and general or corporate management
was the highest, nearly $125,000.
Compensation by numbers of employees managed also increased with number, except for zero,
which also may reflect higher upward salary pressure to attract new engineers.
Figure 4: Company
profits and personal performance were by far the
leading criteria for nonsalary compensation.
Job satisfaction
The majority of respondents, 81%, were satisfied with their jobs: 37% responded that they
thought their jobs were satisfactory, and 44%
CONTROL ENGINEERING
MAY 2016
| 19
2016
COVER STORY
CAREER UPDATE
Salary and non-salary compensation benchmarks

Average compensation by age
Current age
Average compensation by job title
Average base
annual salary
Average non-salary
compensation
Under 30
$58,376
$7,211
30 to 39
$86,113
$8,945
40 to 49
$96,939
$10,276
50 to 59
$94,928
$9,283
60 to 69
$106,100
$10,375
70 or older
$105,592
$26,750
Average compensation by highest level

of education
Highest level of
education
High school diploma
Average non-salary
compensation
Manufacturing
engineer
$57,867
$4,500
Plant engineer
$67,833
$1,967
Owner
$76,467
$25,000
Maintenance manager
$78,983
$5,036
Design engineer
$83,023
$4,977
Electrical engineer
$87,354
$4,159
Engineer
$88,167
$4,000
Chemical engineer
$90,000
$40,000
Average base
annual salary
Average non-salary
compensation
Senior engineer
$90,637
$8,050
Project engineer
$92,489
$7,833
$77,916
$6,750
Plant manager
$92,500
$9,000
Controls engineer
$92,569
$12,456
Other
$93,440
$13,232
Process engineer
$97,565
$6,188
President
$100,000
$35,000
Mechanical engineer
$103,500
$150
Manager
$105,875
$6,075
Project manager
$106,752
$3,480
Engineering manager
$127,654
$11,970
Vice president
$138,167
$13,500
Trade/technical school
diploma
$71,906
$2,444
College attendance
$75,001
$11,928
Associates degree
$78,031
$10,304
Bachelors degree
$99,734
$10,391
Dual bachelors degree
$103,444
$4,922
Masters degree
$104,338
$11,177
Doctoral degree
$109,000
$9,625
Average compensation by number of years

with current employer
Number of years with
current employer
Average base
annual salary
Job title
Average base
annual salary
Average non-salary
compensation
Average compensation by primary job function

Primary job function
Average base
annual salary
Average non-salary
compensation
Non-system integration consulting
$72,975
$5,000
Fewer than 5
$93,404
$7,760
5 to 9
$85,186
$10,176
10 to 14
$94,995
$7,312
15 to 19
$97,882
$6,506
Operations or
maintenance
$86,911
$8,380
$92,486
$11,280
20 to 24
$91,054
$13,586
System integration
25 to 29
$101,196
$8,089
30 to 34
$100,213
$29,971
System or product
design, control or
instrument engineering
$93,080
$10,963
35 to 39
$107,100
$6,400
40 or more
$107,123
$2,333
Other engineering,
including evaluation,
QC, standards, reliability, test, project,
software, plant, electrical, mechanical or
electronic engineering
$95,141
$5,856
Process, production
or manufacturing
engineering
$97,825
$9,552
General or corporate
management
$124,923
$20,708
Average compensation by number of years

in current industry
Number of years in
current industry
Average base
annual salary
Average non-salary
compensation
Fewer than 5
$71,185
$7,123
5 to 9
$80,679
$7,653
10 to 14
$90,059
$13,094
15 to 19
$93,611
$5,839
20 to 24
$99,352
$13,971
25 to 29
$96,651
$7,826
30 to 34
$94,012
$6,031
35 to 39
$99,972
$10,143
40 or more
$111,168
$19,140
Figure 5: Salary and non-salary compensation benchmark tables

break out salary and compensation by age, education, years
with employer and industry, job title and function, and number of
employees supervised.
20
MAY 2016
CONTROL ENGINEERING
Average compensation by number of

employees managed/supervised
Number of
employees managed/
supervised
Average base
annual salary
Average non-salary
compensation
$90,717
$9,809
1 to 5
$90,332
$8,428
6 to 25
$105,808
$9,862
26 to 100
$106,273
$16,345
More than 100
$136,500
$18,000
www.controleng.com
2015 Siemens Industry, Inc.
Learn about
our no
charge code
conversion
services
usa.siemens.com/modernize
Why migrate when you

can modernize?
Smart Manufacturing the Siemens way!
To meet your customers needs, you have to find new

ways to reduce time-to-market, enhance flexibility
and increase efficiency.
Modernizing your automation systems instead
of just migrating to newer components can
help ensure your future success and competitive
advantage today!
Modernization advantages of partnering with
Siemens include:
Siemens industry-leading competitive
advantages the Digital Enterprise, Totally
Integrated Automation (TIA), and TIA Portal
boost ROI, increase productivity, enable
transparency, improve safety, and
strengthen security.
Siemens revolutionary TIA Portal a single
engineering framework that seamlessly
integrates multiple controllers, distributed I/O,
HMI, drives, motion control and data acquisition
and reporting can reduce your engineering
time by up to 30%.
Siemens makes modernizing even easier, with a

comprehensive set of support, training, and
tools including no-charge code-conversion
services and instructions for converting your
current project to the TIA Portal while retaining
your naming conventions, allowing familiarity
from the start.
Siemens offers a comprehensive, competitively
priced automation portfolio that easily integrates
with your existing system to enhance performance,
communications, flexibility, and competitiveness.
From the shop floor to the top floor, Siemens provides the total,
best-in-class solution to modernize your operations.
Digital Factory
2016
COVER STORY
CAREER UPDATE
Job satisfaction factors

Technical challenge
Financial compensation
Feeling of accomplishment
Relationship with colleagues
Job security
Benefits
2016
2015
Relationship with boss

Location
Feeling of recognition
Advancement opportunities
Workload
Leading a team
Figure 6: Top three

job satisfaction factors
are technical challenge, financial compensation, and feeling
of accomplishment.
Relationship with subordinates

Company's financial health
Travel
Managing people
Company size
Physical or ergonomic environment
Other
0%
10%
20%
30%
40%
Areas of operations
Automation and controls
Instrumentation
Highest emphasis
Should have highest emphasis
Manufacturing IT
Maintenance
Energy
Operations
Systems
Human resources
Training, education
Safety
Equipment upgrades
Other
0%
5%
10%
15%
Figure 7:
Automation and
controls should
have ranked highest among areas
of emphasis, but
doesnt.
20%
25%
Highest level of education

High school diploma
Doctoral degree
Trade/technical school diploma
Master's degree
College attendance
20%
4% 2% 7%
4%
6%
13%
44%
Dual bachelor's
degree
Bachelor's degree
Figure 8: Bachelors degree is the highest level of education for 44%.
22
MAY 2016
CONTROL ENGINEERING
Associate's
degree
reported that they love going to work every day;

18% said it was tolerable, and theyre willing to
consider a change; only 2% said theyre heading
for the door at the first chance they get.
The survey found that the top five factors contributing to job satisfaction were technical challenge 39% (down from 44% last year), financial
compensation 37% (up from 28%), feeling of
accomplishment 33% (down from 39%), relationship with colleagues 25% (about the same,
24%), and job security 20% (down from 25%).
Job security was nearly tied with benefits, relationship with the boss, and location all at 19%.
Rounding out the double digit responses were
feeling of recognition 15%; advancement opportunities 12%; and workload 11%. The lowest
reported factors influencing job satisfaction were
physical or ergonomic factors, along with company size, at 2%. The 9 percentage-point increase in
the importance of financial compensation for job
satisfaction corresponded to a decrease in bonuses. See Figure 6 for other factors.
The large majority75%considered manufacturing secure, about the same as last year.
Those with responsibilities in automation,
controls, and instrumentation often have differing views about what areas should get emphasis
compared to those that actually do. According
to respondents, the three areas that get the highest emphasis are operations (29%), automation
and controls (24%), and safety (19%). They felt
automation and controls should get the highest
emphasis (24%), followed by safety (19%), and
operations at 16%. Operations is getting nearly twice the emphasis as it should, and training
is most neglected, getting 2% of the emphasis,
when it should get 11%, respondents said (see
Figure 7).
Education, skills
Survey respondents are well-educated. When

asked about their highest level of education, 44%
have one bachelors degree (another 4% have
two), 20% have a masters degree, and 4% have a
doctoral degree. Other responses included associates degree 13%, some college 6%, trade or
technical school diploma or certificate 7%, and
high school diploma 2% (see Figure 8).
Among engineering disciplines studied
among respondents, electrical or electronic was
the most popular by far, followed by controls,
mechanical, chemical, industrial, and instrumentation, all in double digits (see Figure 9).
Among skills needed to advance, respondents
heartily agreed (69%) that engineering skills are
most necessary, with project management, comwww.controleng.com
munication and presentation skills, computer

skills, and team building rounding out the top
five (see Figure 10).
Outsourcing and why
Nearly 40% of respondents didnt outsource

functions, but when outsourcing was needed, system integration and maintenance were the two
most common at 26% each. (Maintenance was up
5 percentage points from last year.) See Figure 11.
Reason for outsourcing was in a statistical
dead heat among better cost management (43%),
better focus on core competencies (42%), and
lack of skilled staff (40%).
In a separate question about threats to manufacturing business, 8% chose outsourcing, which
was fourth behind the economy (29%); lack of
available skilled workers (13%), which could
lead to outsourcing; and government or political
interference (10%).
Engineering disciplines studied

Electrical (EE)
or electronic
Controls
2016
2015
2014
Mechanical (ME)
Chemical
Industrial
Figure 9: Electrical or electronic

remained the largest
group of engineering
discipline studies.
Instrumentation
Civil
Other
0%
10%
Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com, with
data from Amanda Pelliccione, CFE Media research
director, apelliccione@cfemedia.com.
www.controleng.com
30%
40%
50%
60%
Skills needed to advance
Age, experience, hours
Among respondents, the largest 10-year age

period is 50 to 59 at 40%, up from 37% in 2015
and 32% in 2014. The largest 5-year age period
is 50 to 54 at 23%. The 50s decade had more
respondents than the 30s and 40s combined
(35%). An aging workforce may increase pressure to find enough engineers with the desired
skill sets.
Again in 2016, more than half of respondents
reported working for their current employers for
more than 10 years, the largest single group, and
also like the past two years, were respondents at
their current employer less than 5 years, now 27%.
Continuing up the scale, 5 to 9 years 15%, 10
to 14 years 19%, 15 to 19 years 9%, 20 to 24 years
7%, 25 to 29 years 10%, and 30 or more years 13%.
Similarly, the large majority of respondents
(78%) reported having been in their industry
for 15 years or more, up from 71% last year. The
under 15-year group was 22%, compared to 29%
the year before. The largest 5-year-period respondents in their industry were 25 to 29 and 30 to
34, both 16%.
The average number of hours worked per
week was 45, and the largest group was 40 to 44
hours per week at 39%; 45 to 49 was 29%; 50 to
54 was 15%, and 55 or more was 8%, same as
last year. Fewer than 40 hours accounted for 9%
of respondents. ce
20%
Engineering
Project management
Communication/
presentation
2016
2015
2014
Computer
Team-building
Marketing/sales
Figure 10: Top skill sets needed

to advance are: engineering, project management, communication/
presentation, and computer.
Language
Finance/accounting
Other
0%
10%
20%
30%
40%
50%
60%
Outsourced functions
Maintenance
26%
System integration
Human resources/
recruitment
System management
26%
11%
6%
Logistics/procurement
Asset management
Other
Figure 11: Nearly 40% said theres

no outsourcing at their location;
maintenance and system integration
are most outsourced.
8%
3%
13%
39%
None
ONLINE: See regions, titles, function, company size,

staffing, energy, cybersecurity, and more. Next pages:
Advice from respondents; succession planning.
CONTROL ENGINEERING
MAY 2016
| 23
2016
COVER STORY
CAREER UPDATE
Manufacturing organizations
need a succession plan
Career succession planning: Manufacturing companies need to have more than one engineer
who can bridge the gap between automation and information technology (IT) to keep things
moving smoothly in case one engineer departs.
Ensure people
are assigned
the proper
roles and that
they are given
the time and
opportunities to
learn and grow
their knowledge
of relevant
technologies.
verything seemed to have been going

well recently for a manufacturer. The IT
department and the automation department had an agreement on the separation of responsibilities. Where there was overlap
the impacted group communicated and coordinated any changes with the other group. Systems
that affected both the business networks and the
operations networks were clearly identified, and
there was an understanding of each groups roles
and responsibilities.
However, problems began when a key automation engineer left the company. This engineer also
functioned as the automation departments operations technology (OT) specialist.
Over the first few months, everything seemed
to be running smoothly, but small problems started popping up. The information technology (IT)
group would make a change that impacted production, or the automation group couldnt get access to
systems they needed to update.
The problems became more frequent and longer
to fix as time went on. Eventually, an unexpected
major IT change occurred that stopped production
at the site, which cost millions of dollars. Also, the
automation departments projects started to have
major delays due to an inability to get the proper
IT resources assigned. The result was an antagonistic relationship between the IT and the automation
departments that caused even more delays and production losses.
OT succession planning
MORE
ADVICE
GO ONLINE
At www.controleng.com/archives,
find more under this headline.
At www.controleng.com search
related topics.
24
MAY 2016
The underlying cause of the problem was the

lack of a succession plan for an IT-aware automation engineer. The lost engineer had been
involved because of personal interest, not because
of a formal plan. The automation department
manager encouraged the interaction and knew
that it kept everything going smoothly. With no
succession plan in place, there was no one who
could maintain the inter-departmental communication and coordination. No one in the automation department spoke the language of IT, and
CONTROL ENGINEERING
IT didnt speak the language of automation.

This could happen at other sites if a company
relies exclusively on one person as the OT specialist. Preventing the problem requires that companies develop, implement, manage, and monitor
OT expertise succession plans. OT experts do
not need to know everything an IT expert knows;
they have widely different roles. An IT expert
can focus on one technology and become a master of that area. An OT expert has to have general
knowledge of multiple technologies.
An OT expert should be able to design and
normalize a structured query language (SQL)
database, draw and size a network architecture,
add and modify user accounts, setup and manage virtual machines, have the authority and
knowledge to patch industrial systems, and write
and debug installation and update scripts. This
knowledge base is what is needed in todays technology-rich manufacturing environment.
Define OT roles, understudies
With any luck, a company has someone with

this knowledge and interest. If so, this person
should have a formally defined role and defined
responsibilities. The company should also assign
understudies and have a succession plan in place.
Managements responsibilities are to make sure
that people are assigned the proper roles and that
they are given the time and opportunities to learn
and grow their knowledge of relevant information
technologies.
The understudys responsibility is to be ready
to take over when needed. This could be for a
short period or as a full-time replacement. No
major theatrical group would go into production
without understudies to take over key roles. No
theater understudies are not ready to take over.
A manufacturing organization should be no less
prepared for the unexpected. ce
Dennis Brandl is president of BR&L Consulting in

Cary, N.C. Edited by Chris Vavra, production editor,
Control Engineering, cvavra@cfemedia.com.
www.controleng.com
Engineering career advice from the

2016 Control Engineering salary survey
ontrol Engineering survey respondents provide plenty of

career advice in write-in questions to the 2016 Control
Engineering Salary and Career Survey, covering education,
training, workplace strategies, attitude, communication, engineering tips, project management, and major concerns for the next 12
months.
For the concerns, the write-in responses were divided into
eight categories and assigned one or more categories as appropriate, when the response covered more than one area.
40
19
15
14
9
6
3
2
Economy
Training, safety
Workload, throughput
Hiring, retention, wages, benefits
Technology transition, standards
Asset allocation, budget, energy costs
Politics
Mergers and acquisitions.
Divided into just three categories, socio-economic, personnel,

and technology concerns were nearly evenly split between the
first two, with technology concerns a distant third. Perhaps this is
not surprising; engineers can figure out the technology.
The engineering career advice, similarly divided into categories, with some comments covering two or more topics, covered:
58
42
21
12
9
3
Education, training
Workplace strategies
Attitude
Communication
Engineering tips
Project management.
Respondents offered advice; some practical, some sarcastic,

and some humorous, all of which appear in the online version of
this article. A sampling follows.
Education, training
Education, training.
Constant learning and certifications.
Keep abreast of the latest developments in your field.
Learn multiple disciplines and cross-discipline skills.
Machine expertise.
Need to be skilled in controls and networking.
Science, technology, engineering, and math (STEM) are
required.
Stay on top of emerging technology and trends to prevent your
skills from becoming obsolete.
Remember the first principles. Keep it simple, stupid. If things
appear to be defying logic, your assumptions are wrong.
www.controleng.com
Workplace strategies
Get an engineering degree and then spend time on the manufacturing floor to understand fully your business.
The younger people need to recognize the wealth of information that senior engineers have and should try and learn from their
experiences.
Find something you love to do and then find a job where you
can do that. Keep looking until you do.
Understand that engineering is a job that will ultimately require
either travel or being on call. Decide which you prefer.
Attitude
Admit what you do not know. Learn what you do not know.
Be able to sell your project and always strive to learn new
things, whether it is software or the latest research.
Students in engineering should consider co-ops to see what
is really needed in their chosen field. Engineers need to have
broadened skillsets. In lean manufacturing, the person who can
wear many hats and do each job well brings more value to the
company. It is not necessary to be an expert in EVERY field but to
communicate with the experts is critical. Our true job is communication, from the lowest line worker to top management. A genius
who cannot share ingenious ideas may have less value than a
janitor who mops a floor very, very well.
Learn continuously, seek the type of work you enjoy doing and
then do it exceptionally well. Develop strong troubleshooting and
problem solving skills, communicate well, and build your network. Keep margin in your life, time, and finances. Give back. Ask
forward-focused questions.
Try to learn how to market your ideas effectively to management. They arent always knowledgeable about technical details
and need to be educated about the importance of some ideas.
Engineering tips
Automation and robotics.
Engineering is simple. Dealing with nonengineers, many of
whom are uneducable, is the real challenge.
Project management
Define the scope and keep targets clear.
It is nearly impossible to stem the tide of opinion once it has
ascended to senior leadership. Collect your data early and analyze the results to help you understand the true issues. Spread
the word of those findings quickly. There will be meetings of
discovery rather than mandates from above that do not address
the actual issues. ce
Mark T. Hoske, content manager, Control Engineering, CFE Media,
mhoske@cfemedia.com, with data from Amanda Pelliccione, CFE
Media research director, apelliccione@cfemedia.com.
CONTROL ENGINEERING
MAY 2016
| 25
DESIGNING CONTROLS using customer feedback
Automation products improve

with customer feedback
Improved product automation is a result of customer feedback. As customers give suppliers valuable
product feedback, suppliers will consider many factors that may result in a new feature being added
to an existing product or launch a new product to provide a solution.
f you use automation products, then youve

most likely had instances where you wanted
a supplier to add new features or fix a problem with the product. Customer feedback
can help customers feel as if issues are heard,
can be resolved, and requests are fulfilled.
Below are best practices for gathering information from customers by field sales engineers,
distributors, and product managers. Input can
be taken from sales calls or from product engineers when they get similar change requests in a
short period of time. More requests increase the
likelihood the feature should be incorporated.
Software versus hardware issues

Figure 1: More communications can be added as a
result of customer request.
Years ago, all IDEC PLCs
and select human-machine
interfaces (HMIs) had a
built-in Modbus serial port,
a direct result of a specific
customers request. All figures courtesy: Idec
MORE
ADVICE
GO ONLINE
For related links and more about
improving automation products, read
this article online. In the digital edition, click on the headline or search
the headline at www.controleng.com.
KEY CONCEPTS
Give product feedback to suppliers
Changes to products are considered
based on certain criteria
Giving feedback results in improved
products
CONSIDER THIS
What percentage of product
development is a result of customer
feedback?
26
MAY 2016
Feedback can be divided into two areas

hardware and software. Requests for improvements can be related to either area, although
issues to software-related issues are more prevalent. Software issues are the quickest and easiest
to address. The severity of the bug will determine how it is handled. If the bug is minor, it
will be corrected as part of the next scheduled
upgrade of the programming software. If the
bug is more serious and inhibits a customers
use of the product, a beta release of the corrected software is provided to the customer so the
customer can test the fix.
Software feature requests are regularly reviewed, prioritized, and sent to a product
development team. The complexity of the request
and its overall priority determine how long it will
take to be implemented. High priority requests
may have a turnaround time of just a few weeks.
Software improvement
solutions use cases
Consider an original equipment manufacturer (OEM) that uses programmable logic

controllers (PLCs). The OEM wanted a network protocol for communicating with loop
controllers
At that time, the cost of adding a protocol
converter to allow this PLC model to commu-
CONTROL ENGINEERING
nicate with the new protocol was out of the

question for the customer, and writing ASCII
strings for communication with each loop
controller wasnt acceptable. The PLC manufacturers development team investigated the
possibility of adding the new network to the
PLC as an optional communication protocol
in the programming software and determined
that it was feasible.
Once the development team created this
solution, the OEM ordered PLCs with a custom
part number which included this network communication capabilities. In the next generation
of PLCs, that network became a standard protocol built in to all PLCs offered (see Figure 1).
As another example, an OEM customer worked with the data logging function on a
human-machine interface (HMI), the company realized that it needed more precision in its
data saves than what the software allowed. The
HMI manufacturer discussed the customers
request with the development team and decided
to address the customers needs in the next version of the software.
In regards to next-generation product
improvements, here are two examples. Many
PLCs have Web server capability built in. Customers use specific strings to create Web pages
with numerical displays, bar graphs, trend
charts, buttons, and other graphics. These Web
pages are then available for viewing by utilizing
any Web browser.
However, many customers requested an
easier alternative to create custom Web pages.
Based on feedback, PLC programming software
is available that has a built-in Web page editor that enables users to create elaborate Web
pages using a drag-and-drop method as shown
in Figure 2.
In prior years, only a few micro PLCs supported email functions using third-party email
servers. However, over the years, e-mail servers were upgraded with more encryption, which
no longer allowed micro PLCs to support thirdwww.controleng.com
party email servers. PLC manufacturers now

have built-in support for third-party e-mail
servers, an upgrade requiring a combination of
hardware and software changes (see Figure 3).
Software bugs are addressed quickly, however adding software features takes a little longer.
Hardware improvements are more difficult, as
they cost more and must therefore be considered very carefully.
Complex hardware issues
Most hardware issues are requests for new

features and other improvements, however all
requests cant be fulfilled. In order to determine which improvements are implemented
in the next generation of a product, the number of customers requesting the same change
is taken into consideration. If more than a few
customers are requesting the same change, the
issue will be considered through research and
its feasibility.
First, it must be determined if there are
enough requests to move forward with a products development. This requires visiting customers to collect more detailed information
Half Page Horizontal Non-Bleed ad; 7 x 4.875
Life Just
Got Easier.
including why new features need to be added

to the product or why a new product is needed
at all. Since hardware product development is
costly, suppliers must not only know what the
customer needs now, but what will be needed
in the future.
This customer feedback helps determine if
the request should be an improvement to an
existing product or a requirement for a new
product. It also helps suppliers determine if
they are making the right improvement or
building the right product. Building a product based just on one customers request isnt
always the right path, as it might be very specific for a particular application without widespread applicability to other customers.
Figure 2: Some of
IDECs customers said
it was too hard to create Web pages with the
PLC programming software. The feedback led
to the addition of dragand-drop functionality
for Web-page creation.
The New Experion PKS Orion, coming

soon to a control room near you. Also, visit
us at Honeywell Users Group Americas.
www.honeywellusersgroup.com
For more information, please visit

2016 Honeywell International Inc. All rights reserved.
www.honeywellprocess.com/experion
DESIGNING CONTROLS using customer feedback

After gathering feedback from multiple customers requesting the same hardware improvements, automation suppliers
must determine if the improvement:
Figure 3: The IDEC

MicroSmart FC6A PLC
includes features that
were added to the prior
generation PLC based on
customer feedback.
Is technically viable
Applies to a significant portion of
our core customer base
Will result in enough volume
Will achieve sufficient return on
investment (ROI).
ROI calculations are complex and
involve multiple factors including:
Control
Projected sales
MORE
Length of the product lifecycle

Engineering development costs
Processes.
Devices.
Locations.
IIoT Advantage: Remote Monitoring for Edge Control

Red Lions rugged RAM cellular RTUs push control to the network edge with an easyto-configure event engine that simplifies remote asset monitoring regardless of location.
Trigger I/O or send SMS text message alerts based on real-time operational data
Address harsh environmental conditions with rugged, secure all-in-one platform
Support varied connectivity options from I/O to serial, Ethernet and Wi-Fi
Learn more today at www.redlion.net/RemoteMonitoring
Connect. Monitor. Control. I www.redlion.net

2016 Red Lion Controls, Inc. All Rights Reserved.
Investment in the new production line

Product testing.
In many cases, suppliers make prototypes and ask key customers to test them
and give feedback. Based on the prototype testing, the supplier may modify
the design. This process allows the supplier to fix designs in the prototype stage
and not during the full production phase,
which saves time and money.
For simple products such as interface relays, the prototype testing process
occurs constantly.
Examples are fulfillment of customer
requests for higher contact ratings, hazardous location ratings, and additional
socket requirements.
Customers and system integrators
should speak with automation suppliers
early and often. If the request is very specific to a unique application, it might be
better addressed internally with workarounds or additional components.
However, if the request is something that
would have more widespread applicability, then theres a very good chance it will
be fulfilled. ce
Don Pham, is a product manager at Idec.
Edited by Emily Guenther, associate content manager, CFE Media, Control Engineering, eguenther@cfemedia.com.
28
MAY 2016
CONTROL ENGINEERING
DESIGNING CONTROLS smart manufacturing
Smart manufacturing
is a convergence of things
Smart manufacturing is a convergence of capabilities from multiple areas to enhance
productivity. Smart manufacturing is where smart business processes converge with
smart operational processes, smart equipment, and smart product definitions.
mart manufacturing is growing in

popularity, although it can still be a
confusing concept. To some people smart manufacturing is applying the technology of smartphones,
smart houses, and smart cars to manufacturing
equipment. For others, it is applying information
technologies in supply chains and product development or the development of smart products.
There are many definitions of smart manufacturing because it is not just a single thing, but a convergence of capabilities from multiple areas. This
convergence has the potential to bring massive
productivity enhancements as traditional manufacturing moves to smart manufacturing.
Manufacturing is at the center of many different business lifecycles. There are business
lifecycles for the product development, process
equipment (assets), order management, supply
chain management, and security management.
Each of these activity lifecycles has an element of
production or operation.
Product lifecycle
management
Supply chain management lifecycle
Industrial automation control systems

(IACS) security management
There are multiple definitions for the supply chain lifecycle, but a commonly used definition is the Supply Chain Council (SCOR) model.
(www.apics.org/sites/apics-supply-chain-council)
In the SCOR model, the center activity is make,
which is the process that transforms products to a
finished state to meet planned or actual demand.
SCOR does not attempt to describe every business
process or activity, just those involved in obtaining
raw materials, converting them into finished products, delivering them to the customer, and tracking
all of the raw and final materials (see Figure 1).
Asset lifecycle management
Asset lifecycle management defines the

activities associated with acquiring production equipment, operating the equipment, and
decommissioning the equipment.
There are multiple asset lifecycle management
models, but they all follow the general structure
in Figure 2.
www.controleng.com
Plan
Product lifecycle manageSource

ment (PLM) involves the process of managing all of the
information about a product, including the concept and
design, production, and disposal. PLM has been
used to improve product development, production,
and maintenance for the past 25 years, and the latest
adaptation is smart product lifecycle management,
with an emphasis on smart products (see Figure 3).
Make
Deliver
Return
Figure 1: An example of
a supply chain using the
supply chain council (SCOR)
model. All figures courtesy:
BR&L Consulting
Order-to-cash lifecycle management
The order-to-cash (OTC) lifecycle starts with

customer orders, scheduling the production of
the product, shipping the product, invoicing the
customer, and ends with receiving the customers payment. OTC processes touch multiple key
business performance areas: sales order management, order fulfillment, billing, credit management, and cash collection (see Figure 4).
With the advent of smart devices, connected enterprises, and increased automation, there is
an additional lifecycle for IACS security management. Like many of the other lifecycles in an enterprise, the security lifecycle is a continual process,
responding to new equipment, new software, and
new threats (see Figure 5).
Smart manufacturing
All of the lifecycles mentioned are relatively

independent sets of activities, which all converge
on the make, operate, and maintain activities
of smart manufacturing. Smart manufacturing is
the convergence of:
Smart supply chain management: This is
where materials are tracked throughout the entire
supply chain including production. Smart manufacturing involves collecting and maintaining the
information needed to track all raw materials, all
finished goods, equipment used, and personnel
MORE
ADVICE
KEY CONCEPTS
Smart manufacturing is a convergence of many business processes.
Traditional manufacturing is transitioning to smart manufacturing.
Smart manufacturing improves
efficiencies and minimizes downtime.
GO ONLINE
For more details, related links
and more about smart manufacturing,
read this article online. In the digital
edition, click on the headline or search
CONSIDER THIS
What would it mean for the industry
if all facilities adopt smart manufacturing?
CONTROL ENGINEERING
MAY 2016
| 29
DESIGNING CONTROLS smart manufacturing
Plan
or
design
Acquire
or
develop
Install
or
deploy
Operate
and
maintain
Decommission
or
dispose
Figure 2: The basic structure of an asset lifecycle management model.
Concieve
Make
Design
Service
Dispose
Review and improve

Figure 3: The basic structure of product lifecycle management.
Order
Schedule
Make
Ship
A smart manufacturing system provides complete track and trace information for all manufacturing resources through every step of movement,
testing, production, and produces information to
the corporate or extended supply chain.
Smart asset management: This is where manufacturing assets (production, quality, and inventory movement and storage equipment) are designed
to provide late stage customization and software enabled reconfiguration of capabilities. This
includes the ability to make different products using
the same production equipment. Elements of this
capability are evident in:
Third-generation packaging and filling lines,
which are collections of software-coupled
equipment that can be quickly reconfigured.
Invoice
The use of industrial assembly, pick and place,

and palletizing robots that can be reconfigured online to handle product changes without stopping the production lines.
Receive and reconcile

Figure 4: The structure of order-to-cash (OTC) lifecycle management.
Plan
Implement
Verify
and
operate
Detect
Assess
Audit and update

Figure 5: The structure of
an IACS security management lifecycle model.
Process industries, where recipes are used to

control manufacturing equipment to make different products using the same production lines.
used in the make activities. This identification

information is needed for supply chain optimization and to handle problems associated with returns
and recalls. Supply chain optimization means that
product starts are coordinated with material deliveries, and production completions are coordinated
with material shipments.
A smart manufacturing system is made up of

smart manufacturing assets, which can be software
reconfigured and recipe/workflow controlled. In a
smart manufacturing environment the equipment
is not dedicated to single products, much like the
recipe/equipment integration defined in the ISA
88 standard, to provide production flexibility.
Smart product lifecycle management: This
is where definitions of how to make the product
are not tied directly to specific production equip-
MASSA PRODUCTS CORPORATION

Pioneers in the Field of Electroacoutics
Harness the Science of Sound
Made in the U.S.A.
ment. Smart product lifecycle management provides the ability to quickly move production to
different facilities that may have different equipment layouts and capabilities. This requires a
separation of the definition of what needs to be
done and in what order to make a product, from
how specific equipment is used.
A smart manufacturing system provides the
capability to convert definitions of the physics,
chemistry, biology, and material manipulation,
into the specific instructions needed to operate the production equipment. A smart manufacturing system will use recipes or workflows to
coordinate and control the movement of materials through production stages, allowing for rapid
product changes, flexible manufacturing schedules, and late stage customization.
Smart order-to-cash management (OTC):
This is where all quantitative information about
the resources used in manufacturing are identified
and assigned business value. This includes asset
utilization information, activity-based costing
information, direct and indirect cost information,
and perfect order metrics. Smart OTC management allows the company to determine the profitability of individual products and facilities and to
focus corporate resources appropriately.
A smart manufacturing system collects,
maintains, and makes available the quantitative
information on manufacturing resources associated with specific production orders needed to
perform smart OTC management. This involves
providing real-time or near real-time information as materials are consumed, materials produced, and assets used.
Smart IACS security management: This is
where individual production assets have built-in
Figure 6: Smart manufacturing is a convergence of smart business

processes.
security, controlled network access, application

right management, and patches management.
A smart manufacturing system has secure
devices and networks that can be easily and reliably patched and updated as new threats emerge.
The smart devices can automatically download
approved patches, apply them into an off-line (virtual machine) environment, test their operation to
ensure they dont break anything, and then when
approved, apply them to the production environment. A smart manufacturing system has the
capability to manage tens of thousands of smart
upgradeable devices, with minimal manual intervention (see Figure 6).
Smart manufacturing combines all of the above
capabilities to provide a flexible and adaptive manufacturing environment that includes all operational activities related to production, quality, physical
inventory management, and maintenance. ce
Dennis Brandl is president of BR&L Consulting.
Edited by Emily Guenther, associate content manager, CFE Media, Control Engineering,
eguenther@cfemedia.com.
MassaSonic Sensors Give You Control

Extensive OEM Transducer Portfolio - Adaptable Products for Your Applications - Modular Designs
Our technology can boldly go where no others have gone before!

More than 70 years of experience and over 165 patents awarded in electroacoustic technology
Discover Our New Product Releases

Contact us at 781-740 - 6117 or innovation@massa.com
www.massa.com
DATA ACQUISITION historians and data collection
Process historians can be

an integral part of the IIoT
Process historians are still cutting-edge tools even though they have been around for
many years. They can form the foundation of distributed, cloud-based enterprises and
can integrate with the Industrial Internet of Things (IIoT).
rocess historians are the first step up

the automation pyramid beyond process controls and are the foundation
for turning data into information. Process historians provide the data necessary for powerful data analysis tools to do their
job. Following the current technological trends,
they can even be moved out of datacenters and
into the cloud, part of the Industrial Internet of
Things (IIoT).
Process historian essentials
MORE
ADVICE
KEY CONCEPTS
Process historians provide the data
necessary for powerful data analysis
tools to do their job.
A process historian is most valuable when the data is combined with
analysis tools.
Process data can be made available
for statistical analysis and integrated
with third-party systems using APIs.
GO ONLINE
Go to www.controleng.com to learn
more about process historians and
the IIoT.
CONSIDER THIS
What applications could process
historians serve and what benefits
could they provide?
32
MAY 2016
At its most basic level a process historian is a

database used to store time-series data from an
industrial process. Data is collected either on a
cyclical basis of usually 1 to 10 sec, or as data points
change. Actual values, the associated timestamp
and other information such as data integrity are
written to the historian each time data is collected.
Once the data is in the historian, it can be
accessed in a handful of ways. Many vendors offer
data analysis packages that can be used in conjunction with the historical data for trending, reporting, and various database query capabilities. Most
historians also can be queried directly using existing database systems, such as structured query language (SQL) or stored procedures.
Other tools (big data analysis or machine learning algorithms) can be applied to the data to find
interesting insights not easily obtainable through
other methods.
One option available in the past few years is
to move a process historian out of the plant and
into the cloud using a hosted software as a service
(SaaS). Some vendors offer historian as a service
plan where a historian is configured on a remote
machine and data access into and out of the historian is included with a subscription to the service.
Historians also can be configured on cloud-based
computing services that are managed by information technology (IT) departments.
Both options generally include things like service level agreements (SLAs) to define overall
uptime and automated backup/recovery options.
CONTROL ENGINEERING
The one caveat to cloud-based historians is the

increase of the distance between the process and
the historical data, which requires additional networking resources as well as adding a potential
hurdle to accessing the data in the event of intermittent network failure.
It is possible, though, to have the best of both
options. This is especially true for companies that
have remote systems installed all over the world.
To make it work, though, local historians need to
collect data from the system and feed that data to a
supervisory level historian.
This provides all of the benefits of the cloud
while eliminating the risk of network outages
leading to data loss with local data storage that
can be synced as network connections come back
online. This approach is very popular with solar
companies that are managing thousands of facilities around the world and need to provide data to
their customers and power utilities with a minimal
amount of interruption.
Leveraging information
A historian by itself is not a tremendously useful tool. As described in Oil & Gas Engineerings
5-part Intelligent Automation Series, the real power
of a historian happens when the data is combined
in the historian with analysis tools that turn the
data into information.
The first tool, usually supplied with historians,
is trending. Trends display time series data and the
overall trajectory of data points in relation to one
another. Most trend tools provide basic statistical
analysis capabilities including averaging, integration, and range configurations to show when values have exceeded desired limits.
In addition to trending tools, many historians
include the ability to query historical data using
SQL tools. This opens the door for more advanced
statistical analysis and allows historical data to be
distributed to other programs using application
programming interfaces (APIs). This makes getting process data into reports or Microsoft Excel
an easy task for users.
www.controleng.com
Integrate IIoT, process historians
Historians can also be used to collect

and store information from IIoT devices
accessible through open platform communication (OPC) and message queue
telemetry transport (MQTT) protocols
and, using the various integration capabilities described above, can provide
information back to IIoT devices.
One example of this type of integration using the API interface approach is
in use by a company that manufactures
golf course irrigation pump stations.
Each system in the field has a local PC
running a historian and a webserver. The webserver is configured with a
reporting and trending interface accessible via browsers and mobile devices. It
also has an API exposing historical data
to third-party SaaS system.
The API can be queried with different parameters such as describing date
ranges, specific data points to transmit,
now as the data becomes an indispensable tool? What experience and ideas
can IT and system integration partners
bring to the table to build systems to
provide context for the data? And finally, if a company isnt using a process historian, why not start now? ce
Alex Marcy, P.E., is the owner and president of Corso Systems, a system integration firm based in Chicago. Edited
by Chris Vavra, production editor, CFE
Media, Control Engineering,
What data would be

useful to collect and
how can it be made
available to other
systems?
and login and security tokens to prevent

unauthorized access to the system. The
SaaS application integrates with other
data sources including weather information, irrigation sensors, and GPS units
on landscaping equipment to provide
a cohesive monitoring system for all of
the activities required to maintain a golf
course.
Information pyramid
Using a process historian can be

the first step towards a fully connected
enterprise. Process data can be exposed
to business systems, made available for
statistical analysis, and integrated with
third-party systems using APIs.
Some questions users should ask
include: What data would be useful
to collect? How can this data be made
available to and consumed by other systems? What tools will be most useful to
analyze the data today and a year from
CONTROL ENGINEERING
MAY 2016
| 33
REMOTE DATA COLLECTION process plants, mobility
Optimizing remote
collaboration, monitoring
at process plants
Mobile solutions allow plant supervisors and managers to analyze problems and abnormal
situations at process plants. Users can collaborate to determine ways to improve and optimize
operations without traveling to the site. Mobility is a component of Industrial Internet of Things (IIoT).
MORE
ADVICE
KEY CONCEPTS
Process monitoring allows plant
managers and supervisors to optimize
their facility.
Mobile solutions also allow experts
to optimize operations without traveling to the site.
Mobile technology developments
enable key industrial personnel to
stay connected to their enterprise.
GO ONLINE
more about process historians and
remote monitoring.
CONSIDER THIS
What additional technologies can
plant managers and supervisors use
to optimize their facility?
odays plant floors must have access

to a variety of information, but
they are often burdened with issues
around large data volumes, integration of multiple systems, and security.
As a result, there is a greater need to share expertise across facilities to improve safety as well as
optimize production and recovery.
The goal of any industrial organization is
to improve manufacturing efficiency and productivity. Subject matter experts are becoming
increasingly difficult to locate and companies
need to find ways to use them more efficiently.
Plant supervisors and managers are responsible for the safety and uptime of their facilities. However, in this multitasking era, they are
not usually in front of a computer, looking for
alarms. Often, supervisors and managers are
busy in meetings, visiting customers, and performing other tasks vital to their jobs.
Evolution of process monitoring
Process monitoring is the main building

block of effective plant operations. If something
isnt monitored, it cant be measured, which closes the door to all optimization opportunities.
Mobility brings greater visibility to monitoring systems. The evolution of process monitoring is providing the ability for industrial workers
to easily collaborate with subject matter experts
and monitor and trend process variables right
from a mobile device.
Mobile solutions also allow experts to analyze
problems and abnormal situations and determine
ways to improve and optimize operations without traveling to the site. The engineer can learn
about critical process conditions and bring them
out of the control room, delivering conditionbased metrics to relevant personnel. For example, if control engineers can see a process variable
trending toward an excursion threshold, they
can take necessary actions to mitigate the chances of a potential upset. Neither the process engineer, nor the team he or she is collaborating with,
need to access a laptop or go to a control room. A
smartphone with a smart app is all that is needed.
Advancement of mobile technology
Mobile applications for process monitoring are designed to provide relevant

metrics and the tools to resolve issues directly to mobile devices, helping to
improve efficiency and safety. All images courtesy: Honeywell Process Solutions
34
MAY 2016
CONTROL ENGINEERING
A new generation of mobile applications is

designed to fulfill the promise of the Industrial Internet of Things (IIoT). Users can remotely
receive real-time, customized productivity alerts
from multiple data sources, such as alarm management systems and process historians, and use
this information to resolve problems.
Mobile technology, including industrial mobile
apps, improves situational awareness by keeping
stakeholders abreast of critical alarms and events
in near real time. They are not required to log
into another application, and it is easy to initiate
an all hands on deck approach by forwarding
the alert to others. Robust trending capabiliwww.controleng.com
ties also simplify the understanding of process

excursion details.
The latest mobile apps also drive increased
collaboration. Users automatically see who else
has viewed a notification and initiate a conversation by posting comments about the event.
Any users subscribed to the alert can participate directly from his or her smartphone. A
Twitter-like feed helps figure out who has taken
ownership to help bring the problem to a resolution and manage the incident from a particular location.
Mobile apps can connect to different sources

and applications across
the companys portfolio
to create a more intuitive
mobile experience for
plant workers.
Users automatically see who else has viewed

a notification and initiate a conversation by
posting comments.
Global connectivity to the enterprise
Current developments in mobile technology

enable key industrial personnel to stay connected
to their enterpriseregardless of their location.
The mobile app solutions help bring timely, relevant, and proactive metrics and the tools to resolve
issues and improve efficiency and safety. ce
Rohit Robinson, director of portfolio innovation,

Honeywell Process Solutions. Edited by Chris
Vavra, production editor, CFE Media, Control
Engineering, cvavra@cfemedia.com.
Managers and supervisors can use mobile apps to receive alerts

and monitor performance remotely.
CARLO
GAVAZZI
Automation Components
CARLO
GAVAZZI
SENSORS: Inductive and Capacitive Sensors
Photoelectric Sensors Level Sensors Ultrasonic
Sensors Magnetic Sensors Motion Sensors
Environmental Sensors Wind Sensors
Limit Switches Light Curtains Safety Interlocks
SWITCHES: Solid State Relays Contactors and

Overloads Definite Purpose Contactors Soft
Starters Manual Motor Starters Mini Circuit
Breakers Electromechanical Relays Pushbuttons
and Pilot Devices
CONTROLS: Energy Meters and Transducers

Power Supplies HMIs Digital Panel Meters
Timer Delay Relays Current- Voltage- and Phase
Monitoring Controls Current Transformers Safety
Modules Counters
Whether its our industry leading range of solid state relays, Contact us today, and one of our field sales representatives will
our new HMIs and mini-circuit breakers or our vast offering show you why CARLO GAVAZZI is one of the fastest growing
CARLO
GAVAZZI
of sensors, contactors, power supplies,
and energy
meters, automation companies worldwide. Well be more than happy
CARLO GAVAZZI has the solution for
your
many Fax:
demanding
to provide a free evaluation sample to qualified OEMs.
USA
Tel: 847.465.6100
800.222.2659
Canada Tel: 888.575.2275 Fax: 905.542.2248
application requirements.
Mexico Tel and Fax: 55.5373.7042
www.GavazziOnline.com Info@CarloGavazzi.com
GavazziOnline.com
847.456.6100
Info@CarloGavazzi.com
twitter.com/CarloGavazziNA
facebook.com/CarloGavazziNA
#16 at
www.controleng.com/information
Visit ourinput
website
for
downloadable data sheets,
brochures and pricing: www.GavazziOnline.com
CONTROL VALVE advances
Modern control valves offer

communications, diagnostics
Better designs, modern materials, on-board intelligence, and communications in modern pneumatic
control valves create opportunities and benefits for machine designers but also create new challenges that need to be addressed. Safe, efficient pneumatic automation systems increase machine performance and operational reliability, reducing compressed air costs by almost half, in one example.
MORE
ADVICE
KEY CONCEPTS
Opportunities for machine designers.
New challenges for machine
designers.
Benefits of applying modern control
valves.
GO ONLINE
Machine safety, diagnostics information, and more images appear with
this article online. In the digital edition, click on the headline or search
CONSIDER THIS
Do the benefits of modern control
valves outweigh the challenges for
machine designers?
n old machine design engineer once

sat me down and taught me everything he thought I needed to know
about the science of pneumatic directional control valve selection.
While his approach seemed to have been unsophisticated to machine design, there was a certain
elegance to it. For most machines, a detailed and
exacting approach to the design of a pneumatic
control system isnt going to be the thing that sets
your machine apart from the competition, so spend
as little time on it as possible. Today, smarter pneumatic designs can reduce compressed air use by
nearly half, save space, and save design time.
Modern market expectations require that
each aspect of a machines design takes advantage
of advanced technology, when appropriate. The
advances in modern control valve design and best
practices allow easier implementation without completing a masters course in pneumatics.
Consider the following application: a design
for a machine that requires 48 solenoid valves to
operate a variety of small actuators. The machine
is comprised of several cells along a 10-meter total

length. The customer requires demonstrated energy savings relative to earlier iterations of this equipment. The customer also requires quick and easy
diagnostic capabilities.
The basics of pneumatics
To match a valve to each actuator application,

two basic questions need to be answered:
How fast does the actuator need to move?
This question will help in selecting a valve with
the correct flow rate. A multitude of free, online
tools can help with this calculation.
What needs to happen when power fails?
This question will help select the correct valve
function. Each valve below will cause a cylinder to
extend and retract in the same fashion, but each
will behave differently when power is removed,
such as in an emergency-stop or power failure situation. Its important to select a valve that will provide the right behavior in this situation. It might
make sense for a welding gun to auto retract or for
a door actuator to be vented to allow it to be operated manually (see Table). It should be noted that
rod locks, pilot-operated check valves, and other
devices allow for a wider array of functions.
Valve manifolds
Table:
Table:Trapped
Energy concerns. Compressibility of air results in low position accuracy and drift. All figures courtesy: Festo
36
MAY 2016
CONTROL ENGINEERING
As the design process moves from the actuators

and connected valves to the valve manifolds, and to
the control system, architectural questions need to
be answered. In the past, it was common to choose
a valve family based on the worst-case scenario.
The valve with the largest flow requirement would
set the precedent for the entire valve manifold. In
cases where it was possible to mix valve sizes on the
same assembly, bulky, expensive adapter plates were
required. Advances in valve manifold technology
allow the designer to mix and match valves with
many functions and flow rates on one manifold.
A dense constellation of valve functions on
one manifold can help achieve a simple, space
www.controleng.com
saving, easy to mount, and cost-effective

design. The next task in the design process is to consider certain hidden costs
with those benefits.
Decentralized control
Two competing cost factors must

be considered when selecting how and
where to mount pneumatic valves. First,
one manifold of 48 valves will always cost
less than four manifolds of 12 valves each.
Second, long tubing runs between valves
and cylinders hide surprising costs. Lets
assume that all 48 actuators are 32x100 cylinders that cycle 30 times per minute for
two shifts per day.
Traditional scenario: 48 valves are on
the same manifold and run 8 mm tubing
an average of 3 meters to cylinders. Per
year, $14,270.88 is spent on compressed air.
Decentralized scenario: Four manifolds are installed, each with 12 valves.
Since the valves are closer to the cylinders,
shorter runs are used (500 mm) of smaller (4 mm) tubing to achieve the same cylinder speed. In this case, only $7,365.60 is
spent on compressed air per year.
Costs must be considered. In the early
days of fieldbus valve manifolds, the financial case for centralized valve manifolds
was quite strong. Newer advances in network technology allow multiple manifolds
to share one EtherNet/IP network (from
ODVA) (or other industrial Ethernet protocol) node for surprisingly low cost. The
market has produced a wide variety of
these decentralizing technologies. Each
has its own capabilities and limitations, but
they are an effective tool in driving down
the cost of a multiple manifold design like
the one described above.
Figure: The valve/cylinder combination on the left is the traditional plumbing, and
the modern alternative is on the right.
by many modern valve manifolds is the

option of simply supplying pressure to the
valve manifold in a different way.
The Figure shows two valve/cylinder
combinations. On the left is the traditional plumbing, and on the right is the modern alternative. Applying a lower pressure
to the appropriate side of the valve reduces the amount of air consumption. In the
past this was often impossible, as many
valves required that pressure be applied
at port 1 to supply the valves pilot circuit. In most cases, modern valves receive
their pilot supply from a separate galley,
adding flexibility to create a more energy
efficient design. ce
Sean OGrady is product manager of valve
terminals and electronics, Festo. Edited by
Emily Guenther, associate content manager,
CFE Media, Control Engineering,
eguenther@cfemedia.com.
40150 Watt high isolation AC/DC

power supplies certified for medical
application according AAMI/ANSI
ES60601-1:2005(R), 2 MOPP.
Pneumatic energy savings
Most pneumatic cylinders are applied

in situations that require actuation in only
one direction. In many cases, the actuators are plumbed in a way that causes them
to consume just as much energy retracting from the work as they do to accomplish the work. In the same example, but
using only one bar to retract the cylinders,
air consumption would be reduced from
$7,365.60 to $4,922.88. This isnt a new
idea. For years, sandwich pressure regulators were available at each valve station that
could accomplish this, but the additional capital investment wasnt always clearly justifiable. A better solution supported
CONTROL ENGINEERING
MAY 2016
| 37
Reliable. Available. Now.
tracopower.com
CONTROL VALVE advances
Partial stroke valve testing

Understanding the strengths and weaknesses of traditional partial stroke testing
options helps when looking at how new technology enables advancement, explained
Richard Harvey, in Control Engineering Europe.
P
MORE
ADVICE
KEY CONCEPTS
Partial stroke testing provides a
method of proving the safety and
performance of emergency shutdown
valves.
A hybrid approach resolves some
drawback with two existing technologies.
GO ONLINE
See links with this article on
www.controleng.com; it was
published on March 8, 2016, on the
Control Engineering Europe site.
CONSIDER THIS
When looking at replacement PST
technology, do costs beyond capital
cost factor into the analysis?
artial stroke testing (PST) is an important tool for oil and gas operators [and
other in-process industries and applications], providing a method of proving the safety and performance of
emergency shutdown valves (ESVs). For many
years the technique has helped prove the functionality of final element assemblies by testing a
percentage of the failure modes of the final element assembly. The two most well used tools for
PST do exhibit drawbacks.
PST was originally made possible through
the use of simple mechanical systems that could
only offer testing. As the need for diagnostic capabilities grew, smart systems evolved to
advance PST capabilities. The two main types of
systems, positioners and electronic, offer different approaches, and each makes compromises to
achieve the original goal of demonstrating safe
ESV performance.
Positioners are currently the most common
form of smart PST systems available. They can
be a complex solution as although the device
can easily be configured to give any desired
percentage of partial stroke, other components
may need to be added to maintain the desired
stroking speed. Derived from control valve posi-
tion technology, PST positioners were the obvious choice for an immediate replacement for
mechanical testing, with a built-in capability to
reliably move a valve to a given position.
Improved with the addition of an emergency
shutdown (ESD) function, positioners became a
fundamental part of the control system for an
actuator. PST positioners can create an effective
redundant ESD when used in conjunction with
a solenoid valve.
Compromises in designs
Positioners do not test the valve at the full

designated operating speed, meaning a question
mark exists over the results they produce. Their
use requires a reconfiguration of the pneumatic control, they can only operate across a limited flow rate, and they are not compatible with
all valve types. They also have high safe failure
rates, which can result in spurious trips of the
safety function. Difficult to commission, install,
and service, they also reduce diagnostic coverage, one of the main misgivings of the mechanical systems they replaced.
Many manufacturers and oil and gas operators turned to electronic systems to alleviate
shortcomings. Electronic systems can perform a
partial stroke adequately for an emergency situation, deliver the required level of diagnostics,
and address issues associated with positioners.
Most systems use electronic control boxes, which
connect the power supply to the solenoid valve
and are fitted in close proximity to the actuator.
They de-energize the solenoid valve to perform
the partial stroke test, monitoring either the
valve position or instrument pressure or both to
determine the success of the test.
Despite solving some issues associated with
positioners, electronic systems also have limitations. For example, additional equipment is usually required (such as an electronic control box),
positioners offered the

advantage of the
diagnostic system
being built into
one of the control elements. The
logical conclusion
was to integrate the
diagnostic system into
one of the final element
components and install
the diagnostic system
into a high integrity solenoid
valve. This led to the creation
The hybrid integrates the diagnostic system
into one of the final element components.
making the system more costly and harder to

service. The safety integrity level (SIL) performance also can be compromised through solenoid valve selection while electronic systems can
create a spurious trip risk.
Despite benefits of positioners and electronic systems, neither system could offer a holistic,
fully reliable solution given the inherent safety
risks of oil and gas operations.
Hybrid PST
In developing a hybrid technology, solenoid

valves served as a starting point. Electronic
systems provided simpler operation as no extra
pneumatic components were required, and
of the first fully integrated PST

solution with low safe and dangerous failure rates. The integrated unit combines a high-integrity
solenoid valve with an electronic
control system to provide highlevel diagnostics, simple pass/fail
reporting, and reduced engineering
requirements. It eliminates the possibility of over-stroke. ce
Richard Harvey is business development manager at IMI Precision Engineering. Edited by Mark
T. Hoske, content manager, Control Engineering,
CFE Media, mhoske@cfemedia.com.
Designated
the IMI Precision
Engineering ICO4PST, the unit combines the companys
high-integrity solenoid valve with an
electronic control
system to provide
high-level diagnostics,
simple pass/fail reporting,
and reduced engineering
requirements as well as
eliminates the possibility of
over-stroke. Courtesy: IMI
Precision Engineering
Invented here. Perfected here.

Poorly copied over there.
Were flattered that our competitors have admitted the superiority of Rittals patent-protected modular enclosure system.
With more than 10 million Rittal TS 8 modular enclosures sold worldwide, its clear to see why Rittal is acknowledged as
the industry leader. So why settle for a cheap imitation when you can have the original? Rittalwhen quality matters.
And to our hopeful competitorsnice try.
RITTAL SHIPS QUICK!

Made in the USA
www.RittalEnclosures.com (800) 477-4000
One Class. Rittal Class.
Download complimentary whitepaper:

usa.siemens.com/ids-ratio
Optimizing your process

efficiency?
You can with our motors and drives
Integrated Drive System optimized solution

IDS offer a single-source drive train solution that is engineered for optimal
component compatibility.
IDS has a history of proven success with engineering drive trains for a wide
range of applications in virtually every industry.
usa.siemens.com/ids-ratio
Setting records,
making deals
U.S. presence at Hannover Messe a rousing success
By Bob Vavra
Content Manager, CFE Media
President Barack Obama

and German Chancellor
Angela Merkel share a smile
during the opening ceremony of Hannover Messe
2016 in Hannover Germany
on April 24. Image courtesy:
Hannover Messe
www.controleng.com
he United States waited 70 years to

become Partner Country at Hannover Messe. It was worth the wait
for all parties.
The U.S.s presence at the worlds
largest industrial trade show set
records and established new relationships. More
than 5,000 Americans came across the Atlantic
to experience Hannover Messe, and many came
for the first time. The impression they left on the
show was as strong as the impact of the U.S.s
presence on the event.
From the arrival of President Obama on
Sunday, April 24, to the final footstep on the
fairgrounds on April 29, attendees got a look at
the possibilities of global manufacturing, and
the critical role American manufacturing will
play in realizing those possibilities.
Hannover Messe 2016 has shown that the
United States and Germany are equal partners
in the pursuit of digitalized manufacturing and
energy, said Jochen Kckler, member of the
managing board at Deutsche Messe, at the fairs
closing press conference on April 29. In order

to connect products, machines, industrial enterprises, and people across countries and continents, we need to arrive at universally applicable
technologies and standards. Here at Hannover
Messe 2016, the USA and Germanyalong with
other leading industrial nationshave sparked
the dialogue needed to make that happen.
It was impossible for the 190,000 attendees to
miss the message of Industrie 4.0, the German
framework incorporating many aspects of the
Industrial Internet of Things (IIoT).
This marks the breakthrough for Industrie 4.0,
said Kckler. Next on the agenda is the commercialization phase. The technology is ready to roll,
and about to make its way onto the factory floor.
Big attendance, big ideas
The final attendance at Hannover Messe

exceeded even the most hopeful show officials
expectations. Although this years show did
not include Motion, Drives, and Automation
(MDA) pavilions, attendance was still up from
175,000 in 2014, the last year that
included MDA. Attendance outside
of Germany also increased by 25% to
more than 50,000 attendees.
The roughly 5,000 American
visitors who came in search of new
technology for their manufacturing
plants and energy systems are sure
to have found what they were looking for here in Hannover, and to have
made a lot of valuable new acquaintances along the way, said Kckler.
Industry initiatives from Germany,
the USA, China, Japan, and the EU
have come together here in Hannover
to embark on a shared journey into
the digital future.
One example was the Industrie
4.0 Meets the Industrial Internet
forum, which attracted more than
8,000 attendees.
CONTROL ENGINEERING
MAY 2016
| 41
A dazzling opening
Obamas first attendance to Hannover Messe

was highly anticipated and tightly guarded.
Unlike past years, there was strictly limited
access to the Hannover Centrum, where 3,000
guests and media from around the world were
carefully screened and transported to the venue.
more business with the world, Obama said.

As president, Ive worked to make sure we are
sustaining the spirit of innovation. In addition,
Obama said that the U.S. is now the top exporter
of German goods. We need to build on that
success, he said.
In that light, Obama and German Chancellor
Angela Merkel gave strong endorsements on
TTIP negotiations, which Obama said need to
be completed in 2016. We cant let this opportunity pass, said Obama. The United States
is prepared to make an agreement this year.
Obama and Merkel both said the final TTIP
agreement would raise labor, safety, and environmental standards and improve trade by
lowering barriers. And both acknowledged the
oppositions to the agreement from factions in
each country, including a protest in the streets
of Hannover on the previous day.
The answer is not to pull up the drawbridge
and stop trade, Obama said. We can do trade
the right way. TTIP will not lower standards;
it will raise standards even higher.
A big show, and a big week
President Obama reviews

robotic capabilities at
the Kuka and Weidmuller
booths as part of his tour
of the Hannover Messe
fairgrounds April 25. Image
courtesy: Hannover Messe
42
MAY 2016
Once there, the president received a warm

welcome. Our guest is the biggest economy of
the world, the most important trading partner of
Germany, the United States, said Stefan Schostok, lord mayor of Hannover, who opened the
evenings events. We are proud for very first
time to welcome an American president to our
trade show. Welcome Mr. President.
Obama returned the warmth, and noted the
historical significance of his attendance. Im
pleased that this year, the United States is the
Partner Country for the very first time. I am
honored to be first U.S. president to attend Hannover Messe, said Obama, who noted that in
2016, Germans also are celebrating the 500th
anniversary of its beer purity law. I may join
you in that celebration, he said.
In his remarks, the president declared the
United States is open for business and delivered strong support for the Transatlantic Trade
and Investment Partnership (TTIP).
Obama said the strong economic ties between
the U.S. and Germany began at the end of World
War II, just two years before the first Hannover
Messe was staged. Since then, Obama said the
two countries are each others closest allies in
trade and economic development.
Were ready to do even more business with
Germany, more business with Europe and
CONTROL ENGINEERING
While the United States is looking to highlight

its potential as a global importer of manufacturing companies and jobs, the opening ceremony featured two of Americas great cultural
exports. Members of the Alvin Ailey American
Dance Theater performed interpretive dance
to gospel music, and singers from the Broadway musical, Wicked, performed two songs,
For Good and Defying Gravity.
The opening also included a presentation
where robots and humans worked and even
danced together, a continuation of the integrated industry theme of Hannover Messe 2016.
Another highlight of the week was the celebration of the Select USA pavilion at Hannover Messe on Wednesday night, April 27.
Commerce Secretary Penny Pritzker and U.S.
Ambassador to Germany, John B. Emerson,
welcomed more than 1,000 people to the Select
USA pavilion in Hall 3. It was a night to celebrate and to relax, as more than 13,000 bottles
of beer were imported from the U.S. to help get
the party started.
The party was highlighted by a performance
from the U.S. Army Europe Band and Chorus.
Military personnel in uniform provided an
entertaining night of music. The 10-piece band
played and sang blues, swing, and rock songs
to the delight of the workers from the Department of Commerce and more than 40 state and
regional economic development groups at this
years event.
www.controleng.com
Already paying dividends
According to a Select USA press release, the

Berghoff Group will invest $30 million and
create 100 jobs in Auburn, Ala., at its first U.S.
manufacturing plant. Starting in 2017, Berghoff Precision Machining will produce parts
in Auburn for customers in the equipment
manufacturing, semiconductor, and aerospace
industries.
We welcome middle-sized German companies investing and succeeding in the United
States, said Emerson in a press release. The
Berghoff Group is a family-owned firm with
a strong tradition here in Germany. We are
proud to join that tradition with U.S. productivity and innovationamong the many
reasons foreign firms choose to invest in the
United States.
With the North America operation we will
be able to serve our global customers both from
Europe and the U.S., said Oliver Bludau, CEO
of the Berghoff Group. Berghoff s principles
and processes will create the same quality and
value for our customers for products made at
our Auburn location. We are very grateful to
Members of the U.S. Army Europe Band and Chorus provided the entertainment at the Select USAs celebration at Hannover Messe. The U.S. presence at
the show helped drive attendance up by 25%. Image courtesy: CFE Media
the State of Alabama and the City of Auburn

for the support that our project is receiving.ce
Microsoft wants to lift maintenance function

Partnership with Otis Elevator designed to digitally monitor operations.
By Bob Vavra, Content Manager, CFE Media
Microsoft CEO Satya Nadella sees his companys role in the

Industrial Internet of Things (IIoT) as the platform from which
companies will build their own software solutions.
Philippe Delpech, president of Otis Elevator Co. is in the
business of moving platforms to achieve business success. In
announcing his companys partnership with Microsoft at a press
conference April 24 at Hannover Messe, Delpech said his company will use that digital platform to improve operations and
its workforce.
Otis invented the elevator; without it, New York and Chicago might never existed. There would be no building above
three stories, said Delpech. One of the reasons we have led
the industry for 163 years is that we have been innovative as
a company. We also have been a service innovation. We have
2 million elevators around the world and transport 2 billion
people a day.
Delpech said that if Otis wants to be an industry leader over
the next 163 years, the company has to manage its elevators and
its workforce in a more connected, smarter way.
Otis will expand its existing relationship with Microsoft by
adding cloud computing and smart analytics to its service network, which currently spends 60 million hours servicing the
Otis network of elevators and escalators worldwide.
www.controleng.com
Digital technology is in all of our

lives, all of our businesses, Nadella said.
Its no longer just about us providing a
digital system. Its about Otis using our
digital platforms to create their own digital product. The elevator itself is a digital
product. Every elevator can have analytical ability and predictive ability. That is
what I describe as a system of intelligence. Microsoft CEO Satya
Thats what the theme of this conference Nadella. Image courtesy:
is aboutdigital things being created by CFE Media
industrial companies. Empowering that
transformation is what Microsofts mission is all about.
Nadella said the opportunities around cloud computing and
predictive analytics for manufacturers and maintenance teams will
begin with the software platform, but will be driven by individual
companies such as Otis for their internal needs.
It isnt like we didnt use information before, said Nadella. What
is interesting in this area is the a digital feedback loop that gives
you information on how improve continuously is software-driven.
That digital feedback loop is a now a new capability.
That will create a fundamental change for Otis as its transforms its
two million elevators and escalators from devices that lift people to
interactive machines. The way we are going to maintain the machine
will influence the way we design the machine, Delpech said. ce
CONTROL ENGINEERING
MAY 2016
| 43
Selling your state on the

ground in Germany
Economic development teams find new partners.
By Bob Vavra
Content Manager, CFE Media
Ohio Lt. Gov. Mary Taylor at

the Ohio booth, part of the
USA pavilion at Hannover
Messe 2016. Image courtesy: CFE Media
44
MAY 2016
s a native of the Akron, Ohio area, Mary

Taylor is familiar with manufacturing, and how manufacturing needed
to evolve as many rust belt industries
left the region. As Ohios Lt. Gov., Taylor now
sees the value of a diverse manufacturing sector
that promotes both foreign direct investment
into the state and helps Ohio manufacturers
expand into the world.
Vanessa Goeschl is a first-generation resident
of Charlotte, N.C., whose parents emigrated
from Germany. The combination of her role as
senior vice president of economic development
for the Charlotte Regional Partnership and her
fluency in German made her the ideal representative to explain to anyone who came to the
North Carolina booth at Hannover Messe about
the value of U.S. manufacturing, and Charlottes
role in manufacturing in particular.
Ohio and North Carolina were two of the 40
states represented at Hannover Messe in April.
They were part of the
largest U.S. manufacturing effort at Hannover to date, and
that turnout helped
swell the U.S. attendance to a record
number and increase
overall traffic at the
fair by 15,000 attendees this year.
Wit h Tay l ors
boss, presidential
candidate and Ohio
Gov. John Kasich,
on the campaign
trail, Taylor came
to Hannover Messe
this week as a continuation of Ohios
long support forthe
event and to bring
more business back
home.
Germany is our
best trading part-
CONTROL ENGINEERING
ner, said Taylor. They are very important to

us. We have 25,000 manufacturing jobs in Ohio
just from German companies. Being physically
present at this show lets people see that we are
serious.
At the show, Taylor and her team learned that
German-based automotive supplier the Schaeffler Group committed to a $60 million expansion of its existing Wooster, Ohio, plant, which
will create an additional 250 jobs. Having the
opportunity to come here and visit them and
tour their facility shows how important they are
to us, said Taylor.
Goeschl saw this first trip to Hannover as a
way to tout her citys strength, and its geographic
advantages to potential partners. Its an opportunity for us to be on a global platform like no
other, she said. Charlotte is the center of international investment and on the corridor between
Atlanta and Washington, D.C.
Of the companies weve recruited in the last
year, half of them are international companies.
The number of companies coming to our region
has increased exponentially. This is just a natural
place for us to be.
Changing manufacturing
Taylor has watched Akron and other American cities shake off the rust from the change
in manufacturing and pivot to more advanced
manufacturing. Its a global world, Taylor said.
Siemens is a big presence in our state, but Ohio
is filled with small business manufacturers who
contribute to the auto industry. Were the second
largest state to supply the auto industry, and were
the number one supplier to Boeing and Airbus.
There has been a similar transformation in the
Charlotte area. People tend to think of Charlotte as a financial services, center, but its just as
much an IT center, Goeschl said. In terms of
manufacturing, the area has transformed formed
itself. It used to be furniture, textiles and tobacco.
Today its advanced manufacturing, automotive,
and aerospace. There are many suppliers in our
area with ties to Boeing.
While they compete for potential customers,
both have similar strengths to offer prospective
www.controleng.com
companies. Both have strong educational systems, both at the community college and university level, and both have turned toward advanced
manufacturing as the wave of the future.
Both have also seen great value in this trip to
Hannover. Manufacturing is not dead. Its alive
and well and globally competitive, said Goeschl. A lot of people back home who consider
manufacturing a lesser part of the economy, dont
understand how critical it is to expand this part
of our economy. This show is a clear demonstration on why we should focus on manufacturing.
Really, this is a fantastic show. You can see
really cool advanced technology. You really can
see where industry is headed, said Taylor. Relationship building is important. Being physically
present helps us reinforce existing relationships
and build new relationships. Ohio has a lot to
sell. I absolutely believe being present here is
good for Ohio.ce
Technology changes promise

to reinvigorate manufacturing
Siemens USA CEO offers a personal perspective
on industry during Hannover Messe speech.
By Eric Spiegel, President and CEO, Siemens USA
Editors Note: At the dinner following the annual Siemens press

conference at Hannover Messe, Siemens USA President and CEO
Eric Spiegel shared his thoughts on American manufacturing
and its future from a very personal perspective. What follows
are excerpts from that presentation:
This is the first time that the United States has been the Partner Country for Hannover Messe, and its the first time a U.S.
president has visited. There are a lot of U.S. companies here. And
this gives us a great opportunity to showcase what were doing
around the world for our U.S. customers.
Today I live near our U.S. headquarters in Washington, D.C.
But I was born in the state of Ohio in a town called Youngstown,
and when I growing up, people called Youngstown something
else. They called it Steel Town. This is because, for a good part
of the 20th Century, Youngstown was the second-largest, steelproducing city in America.
In fact, both of my grandfathers came over from Germany to
work in those steel mills. The work back then was dirty, dark,
and dangerous. But it allowed my grandfathers to earn a good
living and join the middle class. One day I thought Id work in
the steel industry too. But before I was old enough, those steel
mills closed. A lot of U.S. manufacturing jobs moved to other
countriesand that hit towns like Youngstown really hard.
So I think my grandfathers would be really proud to see me
working for a large German company thats helping to reinvigorate
manufacturing in places like Youngstown and across the U.S.
Today, the United States is our largest market. Last year
we had well over $20 billion in revenue, including export
revenue of $5.5 billion and we invested more than a billion
dollars in research and development in the U.S. We have over
80 manufacturing and industrial sites, and more than 50,000
employees in the U.S.
www.controleng.com
Eric Speigel, president and CEO

of Siemens USA. Image courtesy:
Siemens
So Siemens is very bullish about

the future of manufacturing and
the overall business environment
in the U.S. And were also particularly bullish about the application
of a new type of manufacturing in
the U.S. or Industrie 4.0, which
Hannover Messe is focused on this week.
The U.S. is now approaching its 10th anniversary of when the
iPhone was introduced. During this time weve seen smartphones
thoroughly transform our consumer and retail worlds. But manufacturing software has become much more sophisticated too.
Looking now 10 years into the future, were going to see
industry make the leap to smart factories. Industry 4.0 will be
powered by advanced robotics. It will be powered by machines
connected by cloud software. But what really makes Industry
4.0 unique is the ability to use software programs to visualize
and design products.
The most effective way to design productseven factories and
shop floors is no longer by investing in all the material and building expensive models. Its on a computer screen. And the U.S. has a
rich environment for this new type of manufacturing to flourish.
Whereas a country like Germany leads in machine tools and
robotics, right now the U.S. stands out as a leader in software
innovation. More than 75% of software revenues are generated
by U.S. companies, and many of the largest companies in the
world. Google, Apple, Microsoft, Facebook, are basically software companies. This is where the value is migrating.
But there is one big obstacle that U.S. manufacturing has to
overcome. Although some U.S. companies are moving rapidly
Continued on page 46
CONTROL ENGINEERING
MAY 2016
| 45
Continued from page 45

towards Industrie 4.0and Ill mention somemost firms
are still running on aging technology. Today, the average
age of U.S. assets and equipment in operation are more than
35 years old (and) $65 billion worth of automation systems
are reaching the end of their useful life. And only 5% of U.S.
companies have implemented a big data analytics strategy.
So the U.S. industrial base is ready for a big overhaul.
The result for customers is a fully flexible production
line that can change the configuration of products routed
through the industrial process without interruption.
And we are already helping some companies lead the
way into this fourth industrial revolution.
With Ford, we partnered with the automaker to develop
software that helps engineers simulate the entire assembly
process for vehicles at different plants. This has contributed to Fords emergence as a leader in designing flexible
production.
Henry Ford once famously offered its Model T In any
color you want, so long as its black. Today, with the help
of our software, Fords F-150 pickup truckAmerica
best-selling vehicleis built to customers specifications
in millions of possible configurationswhat we like to call
mass customization.
So Ill end there except to say that we have a very aggressive agenda to help our U.S. customers large and smallto
gain the competitive advantages attached to digitalization. ce
Poland to be 2017
Partner Country
By Bob Vavra, Content Manager, CFE Media
HANNOVER, GERMANY: Poland will be the 2017 Partner Country at Hannover Messe, meaning that next years partner will come
across the border instead of across the Atlantic.
The formal announcement came Tuesday, April 26, as officials
from Hannover Messe and Polish economic development signed
the official documents.
Many sectors of Polish industry are achieving impressive innovation and growth. This presents a range of opportunities for businesses and investors all around the world, said Deutsche Messe
managing board member Jochen Kckler. Hannover Messe is the
ideal platform for highlighting these opportunities and hence for
putting the strengths of the Polish economy in the international
spotlight and building closer economic relations, both multilaterally and bilaterally between Germany and Poland, said Polish
Undersecretary of State Pawel Chory.
One of the Polish governments most important priorities is to
support innovative Polish companies and help them expand internationally. The international industrial trade fair in Hannover gives
Polish companies an excellent chance to showcase their technologically
advanced products and engage with valuable contacts.ce
Our Heart Is Set On

Your Productivity!
Winner
2015
We Deliver Results In Productivity
www.forcam.com
INSIDE PROCESS advanced process control
Part 2:
Neural networks in
process control
Neural network technology can resolve the most nagging process control problems. Prepare
the dataset for training, neural network model training, and validation. Implement a neural network model on a control platform and human-machine interface (HMI). See also Part 1, covering neural network architecture, control space, model range, data types, and dataset selection.
n setting up a neural network for process control, at the end of Part 1, parametric testing was
completed and the data stored in the historian.
The objective, and next step, is to obtain a record
dataset for training and validating the neural
network model.
Parsing is the primary preparation step for dataset training. After the record dataset has been constructed, it must be prepared to train the neural
network model. The record dataset should be randomly parsed into three separate record subsets:
training, test, and validation (see Figure 1).
Both the training and test datasets are used in
training the model. The neural networks training
algorithm uses the training subset to converge the
model to the target function solution. The test subset is used to prevent over-training that could affect
the robustness of the model. After the neural network model is trained, it must go through a strong
validation process to give the user confidence it will
perform well when in service. The validation subset
proves the model can approximate the target value
using data independent of the training process.
The training subset is composed of 60% to 80%
of all the records. The remaining records are usually
a split between the test and validation subsets. Each
record should be randomly chosen from the dataset and placed in one of the three subsets. (Test have
shown improved results when there is an equal percentage of records in each subset that are above and
below the medium of the target reference.) After a
record is selected, it is removed from the original
dataset so it cant be selected again.
Training, validation, reporting
Now that the subsets are created, there are four

steps that must be carried out during each training
iteration:
1. Initialization
2. Normalization
3. Training
4. Testing for over-training (early stopping).
www.controleng.com
Original
dataset
Random
Random
Random
Record set 1
Record set 2
Training
dataset
Test
dataset
Validation
dataset
Record set 4
Record set 1
Record set 2
Record set 3
Record set 5
Record set 4
Record set 7
Record set 5
Record set 6
Record set 6
Record set 8
Record set 6
...
Record set 12
Record set 10
Record set 9
Record set n
Record set 17
Record set 14
Record set 11
...
...
...
Record set n
Record set n-1
Record set n-2
Record set 3
Figure 1:
The record dataset should be randomly parsed into three separate record subsets:
training, test, and validation. All images courtesy: Process2Control LLC
MORE
And three steps post-training:
ADVICE
1. Validation
2. Training report
3. Training analysis.
Initialization: Before training can occur, the
neurons must be initialized by randomly seeding
their weight and bias values. Initially, random seeding is deemed best because the target function is
unknown.
Normalization: All variables, inputs, and target
references are normalized prior to being used in the
model for training. Normalization scales each input
to the limits of the hidden layer transfer function.
The model output is converted back to engineering
units by unnormalizing the output.
KEY CONCEPTS
The dataset contains a set of
correlated inputs to the target.
The dataset then must be parsed
into three subsets: training, test,
and validation.
Training is an iterative process
with robustness and validation.
GO ONLINE
Link to more online resources,
on neural networks at
www.controleng.com/archives,
under May 2016.
CONSIDER THIS
When is the proper time to stop
the iterative training?
CONTROL ENGINEERING
MAY 2016
| P1
Alternate control
(PID algorithm)
(manual mode)
(last good)
Neural network
controller
1
T
Alarm bit
high correlation. Regression curves should show

a good relationship between the model and target. If the model is out of phase or has a large
error, the model should be retrained, starting
with randomly parsing the dataset for training. A
continued poor result is a clue to more neurons
in the hidden layer and/or reexamine the process
variable selection as described in Part 1 (dataset
selection).
Implementing a neural network model
Figure 2: Manual or
automatic switching to an
alternate control strategy
may be required if entering an untrained control
space.
P2
MAY 2016
If the perceptron uses a sigmoid function, the

normalization is between 0 and 1. If using a hyperbolic tangent sigmoid transfer function (tansig),
normalization is between -1 and +1. The engineering unit range of each process variable is scaled to
the normalizing limits.
Training: Recall from Part 1 that the perceptron uses weights and bias values to compute its
response. The final values are generated through an
iterative back-propagation process. During training, the weight and bias values are adjusted to minimize the sum of square errors (SSE) between the
target function and the model.
Training algorithms that use optimization routines find the best path toward the SSE global minima. However, occasionally, they find a local minima
and get stuck. This is due to the random seeding of
the weights and bias values, the underlying function, and the path taken by the optimization algorithms. If a local minimum is encountered, the
model will show poor correlation with the target
and the training session must be repeated.
Early stopping: Early stopping is a training
cycle exit strategy intended to allow an optimum
reduction in SSE from the training data while keeping the model robust and preventing overtraining.
Regulation: Regulation is a technique that
penalizes weights that become large during training. Although it has merit, early stopping is sometimes preferred as a means of improving robustness.
Validation: Validation is the most important
and final part of confirming that the model will
perform as expected. The validation subset is independent of the training cycle and is used to generate a validation plot. Upon inspection, if the model
is in phase and within close approximation of the
target, the model can be deemed good. The validation curve is the last part of the training report.
Training report: Training reports should be
expected for all models. A report should include
the record dataset, the neural network architecture, the final training plot, and the reduction in
SSE per iteration for the training and test subset for
regulation.
Training analysis: The model and the target
should be in phase, have a small error, and have a
CONTROL ENGINEERING
Considerations for implementing a neural network in an industrial application include:

Configuration of the neural network
Quality check of the inputs
Validation of the control space
Planning an alternate control/
measurement strategy
Appropriate user interface.
Algorithm: Most control platforms have the
instruction set to program the neural network algorithm. The number of neurons in the network is
established during training, and the equation for a
single neuron in the hidden layer is shown in Equation 1 with P being the input vector. Each of the
hidden layer neurons produce an output that is an
element for the A in the output layer equation
shown in Equation 2. The calculated result of Equation 2 is the model of the target variable.
Equation 1
Fsigmoid(P x W1,nT + bias1,n) = an
Equation 2
Flinear(A x W2T + bias2) = Model output
Quality checksinputs: Any model depends
on reliable and accurate inputs. However, neural networks will happily accommodate inaccurate, skewed, or biased inputs as long as they are
repeatable and the model is trained with the imparity. This implies that all inputs should be calibrated
before the training dataset is acquired to establish a
known baseline. During operation, all inputs into a
neural network model should be validated as good
quality by the control system.
Control space testing: In an operational model,
a test must be performed proving the inputs are
in valid control space. Recall from Part 1 (control
space), a model only has knowledge in the control
space where it was trained. An efficient method of
testing is using a set of centroid point vectors with
tolerances. The centroids and their tolerances are
generated from the point vector distribution.
www.controleng.com
integrated
h
intouch bu mi
ndles
g
n
i
t
c
e
t
i
h
c
r
A
Solutions
Applicat
ion
Assista
nce
Superior
Technical
Support
Wonderware
Acceler
Speed- ated
To-Mar
ket
Distributor
Wonderware Distributors Possess Powerful HMI

and SCADA Capabilities for your Automation Projects
Wonderware Distributors have been known to pull off some heroic automation
feats for their customers. One of their most powerful capabilities include the
integrated, InTouch HMI Bundle a pre-packaged and ready-to-go solution for
real-time success in plant operations. North American locations include:
NorCal norcal.wonderware.com 866.966.3376

PacWest wonderwarepacwest.com 888.449.0494
West wonderwarewest.com 713.209.8884
Great Plains logic-control.com 913.764.4400
Midwest wonderwaremidwest.com 866.826.9725
Canada East wonderwarecaneast.ca 905.829.9300
Cincinnati atrdistributing.com 513.353.1800
North wonderwarenorth.com 877.900.4996
Southeast insource.solutions/wonderware 877.467.6872
Ask about our Integrated

InTouch HMI &
Hardware Bundle
2016
WINNER

A
tion of the operator if performance is acceptable.

That is because the errant input influence on the
model is effectively clamped by the hidden layer
transfer function.
Operator interface
It is recommended the human-machine interface (HMI) should have:
Figure 3: Humanmachine interface (HMI)

for a virtual instrument (a)
and an input/multiple output (MIMO) controller (b).
Alternate control/measurement strategies:

Recall from Part 1: Neural networks in process
control that a valid control space can lead to an
invalid point vector outside the control space. If
the input point vector is outside the valid control
space, an action plan should be in place to mitigate untrained model results. There should be an
alternate control or measurement strategy. Figure
2 shows a model base controller strategy thatif
outside its control spacealarms the operator and
automatically switches to an alternate control algorithm. Switching could also be left to the discre-
The model output value

An overall control space alarm indication
Individual first out alarm for each input
A manual mode
An alternate strategy selection for the
output value.
With a virtual instrument interface, the alarm
annunciates on the HMI faceplate (Figure 3a),
showing which input caused the issue. A transfer
is available in case the operator chooses an alternate strategy. A manual mode is available to hold
the last value. The multiple input/multiple output
(MIMO) controller shown in Figure 3b is similar,
but shows the trends of the control and manipulated variables. A separate setup screen is recommended for entering constraint limits and other
alarm settings.
ENGINEERED FOR
D
RE
E T HE RISK
OF
SAFET Y
UC
OC
AR
Allied Mouldeds new HMI Cover Kits are designed to provide protection
C
for instruments or electronics requiring routine attention or detail. Use of
H
FL
ASH & S
such a cover kit reduces the risk of arc ash by eliminating the need to fully
open an enclosure to view electronics or perform maintenance on a system.
Nonmetallic Enclosures & Premium Accessories
The cover kit features a strong and rigid design, mounting securely to the outside of
any enclosure, and makes accessibility to electronic components easy.
Available in two sizes, HMI Cover Kits are UL recognized and maintain
a NEMA Type 4X seal, and are well suited for outdoor applications.
Multiple cover latching options are also available, including
a hinge screw, tamper proof screw, and snap latch model.
All are available in solid opaque or polycarbonate
Scan the QR code
thermoplastic clear covers.
to learn more!

2016 Allied Moulded Products, Inc.
www.alliedmoulded.com
My operators have poor visibility to

potential issues.
They need to view, process, and make
informed decisions - clearly and quickly.
YOU CAN DO THAT

Improve operations performance. Operator performance can impact plant
safety and process availability. Emerson sets your operators up for success by using best-of-class
technology, proven processes, and an understanding of human limitations and strengths. The DeltaV
distributed control system can help reduce operator stress, limit human error, and provide intuitive
data to run your plant more efficiently. Better visibility better performance. Learn more at
www.emersonprocess.com/operationsperformance/
The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2016 Emerson Electric Co.
values for each neuron are provided by the training process. A validation report should be reviewed
prior to implementation on the control platform. A
validation report should show the target reference
in phase with the model with small error.
Many neural network training programs operate on desktop computers. Most control platforms
have the necessary instruction set to configure a
neural network model. Where possible, coding
the neurons on the control platform should be
in subroutines enabling reuse of code on future
models. In operational models, inputs should be
checked for goodness of quality and valid control
space. An alternate strategy should be considered
if inputs are outside of the valid control space.
The HMI should show the model output,
inputs, alarms, set points, auto/manual selection, and normal/alt strategy controls. Trends
and first out logic is valuable for operational awareness and diagnostics. A separate setup
screen is recommended to enter constraints,
alarms, and limits. ce
Using neural networks
Most control
platforms have
the necessary
instruction set
to configure a
neural network
model.
In many process control applications, the

approximate function neural network architecture is simple and works well modeling industrial
processes. Neural networks must be trained from
datasets best obtained by parametric testing. The
user selects the target process variable to be modeled and assembles the training dataset to cover
its range and function. The dataset contains a set
of associated inputs that correlate to the target.
Inputs used in training define the neural network
model control space.
All dataset records are time-stamped with the
target reference value capture time. Datasets are
tied to the equipment configuration at the time of
acquisition. Proper selection of the model inputs
is important to increase the model robustness,
eliminate noise, and reduce cost. Calibration
should be completed on all inputs prior to data
acquisition to establish a baseline.
After the dataset has been acquired, it must be
parsed into three subsets: training, test, and validation. Training a neural network involves backpropagation of the error between the model output
and the target value. Training is an iterative backpropagation process that requires strategies for promoting robustness and validation. Weights and bias
Jimmy W. Key, PE, CAP is president and owner of

Process2Control LLC in Birmingham, Ala. Edited by
Jack Smith, content manager, CFE Media, Control
Engineering, jsmith@cfemedia.com.
PROTECT PUMPS
DRY RUNNING CAVITATION BEARING FAILURE OVERLOAD

MONITOR PUMP POWER
Best Sensitivity
Digital Display
COMPACT EASY MOUNTING

Only 3.25" x 6.25" x 2"
Starter Door
Panel
Raceway
Wall
TWO ADJUSTABLE SET POINTS

Relay Outputs
Adjustable Delay Timers
UNIQUE RANGE FINDER SENSOR

Works on Wide-range of Motors
Simplies Installation
4-20 MILLIAMP ANALOG OUTPUT
WHY MONITOR POWER INSTEAD OF JUST AMPS?
PUMP POWER
Power is Linear-Equal Sensitivity

at Both Low and High Loads
NO LOAD
PUMPING
AMPS
POWER
VALVE CLOSING
FULL LOAD
No Sensitivity
For Low Loads
NO LOAD
VALVE OPENING
NO FLUID
FULL LOAD
CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247

WWW.LOADCONTROLS.COM
INSIDE PROCESS high-performance HMIs
Part 1:
Developing
high-performance HMIs
This two-part series examines the development of high-performance human-machine interface (HMI)
methodology. Part 1 covers HMI evolution, security, improving usability, and consistent use of color.
MORE
ADVICE
KEY CONCEPTS
Using charts and graphs can
enable operators to estimate the
behavior of a variable through time.
Analog values are better understood
when presented graphically.
Use colors that grab the attention
of operators to indicate critical and
relevant statuses in a process.
GO ONLINE
Many more images, examples and
links, appear with this article online at
www.controleng.com/archives, under
May 2016.
CONSIDER THIS
How effective are the HMIs in your
plant?
n recent years, interface design has evolved from

terminals controlled by command prompts to
eye-movement control, where learning is almost
instantaneous. This evolution results from
numerous studies and research in many fields of
knowledge. How can industry benefit?
Many industrial interfaces are developed under
certain short lead-time and constrained budget scenarios, which are outside influences that affect how
interfaces are designed. This makes development
driven by effectiveness, efficiency, and user satisfaction much more difficult
High-performance human-machine interface (HMI) methodology is posed to bridge this
gap by combining state-of-the-art interface design
with aviation industry experience. The most visible features of such interfaces include (Figure 1)
optimized colors, highlighted alarm signals, minimalistic-drawn objects, extensive use of charts and
bar graphs, values displayed within a context, gridbased screens, and efficient use of space.
Figure 1: The most visible features of high-performance HMIs include optimized colors, highlighted alarm signals, effective use of charts graphs, and
efficient use of space. All images courtesy: Elipse Software
P8
MAY 2016
CONTROL ENGINEERING
Using this approach has advantages beyond aesthetics. They include fault prevention, reduction of
operational errors, increased operational efficiency, greater ease of learning, improved information
quality, and lower cognitive-processing cost.
Tests comparing high visual performance HMIs
to traditional HMIs show results too remarkable to
be ignored. This methodology can be applied gradually (or to just a few parts of an already existing
system instead of starting from scratch) creating an
attractive cost-benefit relationship.
Focus on security, awareness
A safe industrial interface must have good

usability. When developing an industrial interface,
users must be considered first and the process second. HMI usability must be good in normal and
critical situations. Therefore, it must be developed
with users in mind.
ISO 9241-11-1998: Ergonomic requirements
for office work with visual display terminals (VDTs)
defines usability as a combination of effectiveness,
efficiency, and user satisfaction in a system. This
same standard indicates usability measurements:
Easy to learn, easy to memorize, and low error rate.
Many accidents happen due to human errors.
When an interface is properly designed, it can
help avoid many tragedies by enhancing the situational awareness of an operator. This way, an HMI
may effectively contribute to an increase in security and safety. Situational awareness means being
fully conscious of our surroundings. It is the perfect
tuning between a perceived situation and a real situation. Becoming situationally aware involves perception, comprehension, and projection.
First, we perceive a fact. Next, we must comprehend it in its context; that is, whether that situation
is normal or not, or whether it is near an abnormality or not. Then, we must project the consequences
of that perceived fact in its context to decide which
action to take and its urgency. How do we implement these three aspects in an interface?
Raw data gives us perception about a value.
However, it does not show us if this value is inside
a normality or on the brink of an alarm. It does not
offer a context.
www.controleng.com
Comprehension can be achieved by

indicating alarm limits to make the range
of operation in normal conditions of a
monitored variable clear to an operator.
This indication of context can be displayed
in several objects, such as graphs, radar
charts, or bar graphs. However, these limits
still do not allow a projection of the consequences of a monitored behavior; they do
not point to a variables trend through time.
A projection can be achieved in several
ways. An intuitive way is by using a chart,
which can estimate the behavior of a variable through time (Figure 2).
to solve an emergency. In an industrial process, this is not recommended.

This is the reason we must always avoid
screens with too many colors and objects.
This prevents the efficiency of an interfaces informative function, thus diminishing its usability. Therefore, when we do
not need to know the exact value for each
point, it is preferable to represent similar or
correlated analog values in a graphical way

(Figure 3). Another object that offers a
good view on correlated variables or even
key performance indicators is a radar-type
chart. In such a chart, the continuous line
indicates the status of the process, at every
instant. The dotted line indicates the ideal
situation and compares how close to the
ideal for each variable is at every instant.
Improving usability
An industrial HMIs main purpose is

to allow users to interact with a process.
This includes efficiently alerting an operator when something is wrong in a plant. To
accomplish this task efficiently, an interface
must alert the operator about what is effectively important. It must not catch users
attention to something irrelevant while
signaling a failure, for example. Using preattentive design techniques may increase
this efficiency. But what is this?
Our brain processes and stores visual information received from our eyes.
Researchers have created a model to simulate this functionality containing a memory
called iconic or sensorial. In this step, there
is a very fast processing of the received
visual information. This is when we perceive something, even if it is a glimpse, or
when something catches our attention.
Next, information is transferred to our
short-term memory (STM), where it can
either be discarded or stored in our longterm memory. STM is limited and temporary. Information does not last very long
in this type of memory. If we overload an
operator with unnecessary visual information, STM is saturated, and it must discard
old information so that new information
can be stored. When information is lost,
the discarded information may be essential
Figure 2: Using charts and graphs can

enable operators to estimate the behavior
of a variable through time.
CONTROL ENGINEERING
MAY 2016
| P9
INSIDE PROCESS high-performance HMIs

Consistent use of color
Figure 3: Analog values are better understood when presented graphically.
Figure 4: Use colors

that grab the attention of operators to
indicate critical and
relevant statuses in a
process.
The most important data must always stand out

from the less important data. To do so, use muted
colors for screens, avoid color gradients, and use
attention-grabbing colors for critical and relevant
statuses (Figure 4).
Objects rendered in a very realistic way may
present two types of problems. The first problem
is using bold colors; the second problem is using
too many pixels for decorative purposes. A simpler,
more efficient representation can be used without
decorative pixels or color gradients. The goal is to
value the use of data pixels and drastically reduce
the use of decorative, nondata, pixels.
Avoid color gradients on screen backgrounds
because context affects color perception. Two rectangles of the same color can easily be perceived as
different shades due to background color variation.
Part 2: Developing high performance HMIs
will focus on accuracy versus context, accessibility,
visual hierarchy, animation versus static indication,
and 2-D versus 3-D screens. ce
Helcker Goetz is an analyst and designer for

Elipse Software. Edited by Jack Smith, content
manager, CFE Media, Control Engineering,
jsmith@cfemedia.com.
CONTROL ROOM CONSOLES

THAT PUT YOU IN CONTROL
From single control room consoles to the largest integrated command

centers, only Winsted has more flexible solutions for you to meet your
exact requirements for function, style and cost. Select the configuration,
design and features you want in modular, modified or full custom console
environments. WITH WINSTED YOURE IN CONTROL.
Choose from 6 modular platforms built to order, or design your custom consoles
Versatile Slat-Wall
Accessory Mounting
Monitor Mounts
to 63-inch, Up to
Full Video Walls
19-Inch Rack
Mount Solutions
Articulated Tilt/Pivot
Monitor Versatility
3 Monitor Mount
Post Heights
Curved, Corner or Linear,

Multi-Bay Configurations
Integrated Power
and Data
Multiple Work Surface

Options and Styles
Accessible Cable
Management Solutions
Dozens of Accessories,
Hundreds of Configurations,
Unlimited Possibilities
End Panel Color, Material

and Graphics Options
PC/Device/Instrument Security
with Swing-Out Authorized Accessibility
WEB: winsted.com
Multiple Depths
and Configurations
Standard Modular, Modified

or Full Custom Console
Solutions
EMAIL: info@winsted.com TEL: 800.447.2257 FAX: 800.421.3839
FREE 3D DESIGN SOFTWARE & DESIGN SERVICES
Download our free WELS 3D software that lets you design, visualize and cost
your ideal control room solution. Or contact us for free design services.
GET IT AT: WINSTED.COM/WELS

More resources posted daily at:
www.controleng.com
digital edition
Exclusives, Online Extras: Benefits of the Control Engineering Digital Edition include
tablet-friendly viewing (HTML5), exclusive content in every issue; headlines link to the
longer version posted online; links are live where a URL is provided; and an email link
arrives when ready. In addition, link to additional Online Extra articles.
DIGITAL EDITION EXCLUSIVES
DE1 How secure is the Internet of Things?
The Internet of Things (IoT) is on the cusp of making our lives easier as consumers and
business professionals, but these is also a very real cybersecurity risk that needs to be
addressed.
DE3 Getting ahead of the IIoT cybersecurity curve
The Industrial Internet of Things (IIoT) offers many potential benefits, but it also poses
many potential risks from a cybersecurity standpoint, and many companies are slow to
realize this drawback.
DE5 Financial benefits of combining automation and safety projects

Collaborating on seemingly disparate projects could help companies save money by having the different
departments focus on areas where their interests and agendas overlap.
ONLINE EXTRAS
(Click on the headlines or search www.controleng.com.)
Support-focused enterprise controls: template design strategies

Highly productive manufacturing processes rely on standard, controller-based system applications. These
applications must appeal to the technicians and engineers who will need to understand, interact, and support
functioning programs whether theyre independent or interdependent programming strategies.
Depth sensor filters out ambient infrared light for outdoor use
Researchers at MIT have developed an infrared depth-sensing system built from a smartphone with a laser
attached that can work outdoors as well as in, which could be beneficial for future field activities.
Are you a 21st-century leader?

Leaders can position themselves as leaders rather than waiting.
Researchers find cause of sour oil and gas

Researchers at Rice University discovered that using biocides to prevent hydrocarbons from souring is causing
an unnecessary environmental burden and offer solutions to create a more effective approach.
IIoTs power found in controllers, HMIs

Technology used to deliver information to the operators fingertips.
Dashboard offers visibility into long-term asset reliability

An asset-integrity dashboard allows rig operators and maintenance personnel to more easily make strategic
decisions that extend asset life and minimize downtime.
www.controleng.com
CONTROL ENGINEERING
MAY 2016
| 57
DIGITAL EDITION exclusive
How secure is the
Internet of Things?
The Internet of Things (IoT) is on the cusp of making lives easier, but there
is also a very real cybersecurity risk that needs to be addressed.
MORE
ADVICE
KEY CONCEPTS
Internet of Things (IoT) devices,
forecast to grow to 50 billion units
by 2020, are a potential goldmine to
hackers.
Cyber security risks notwithstanding, the benefits of the IoT far
outweigh the potential negatives.
Companies need to be proactive in
auditing and managing devices that
use the IoT.
GO ONLINE
related topics.
CONSIDER THIS
What additional safety and security
measures can companies take with
regards to the IoT?
DE1
MAY 2016
nformation security is a huge topic of conversation right now, and its about to get even
bigger. Edward Snowdens leaks on government surveillance and huge data breaches at
Target, JPMorgan, TalkTalk, and others made
the subject front-page news, and that is likely to
continue given the proliferation of the Internet
of Things (IoT).
IoT devices, forecast to grow to 50 billion
units by 2020, offer consumers and businesses
huge amounts of convenience and benefit, but to
hackers they are also a goldmine. This is because
such devices represent another piece of hardware
or software that can be compromised and lead to
stolen data or money.
The early signs of IoT security are not
encouraging; researchers have already managed to hack everything from Googles Nest to
an Internet-connected doll and Canon printer,
while significant and exploitable software vulnerabilities have also been found in Wi-Fi light
bulbs, smartwatches, and Internet-connected
baby monitors.
There have been questions too on how this
affects businesses, if the likes of Nest and Hive
are connecting to enterprise Wi-Fi networks.
Security experts have been quick to voice their
fears over the IoT, with many pointing the finger
at device manufacturers.
Insufficient device cyber security
A recent study of 7,000 information technology (IT) professionals by cyber-security association ISACA found that 75% thought IoT device
manufacturers were not implementing sufficient
security measures devices, while a further 73%
said existing security standards were inadequate.
BH Consulting managing director, Brian

Honan, joined the chorus of discontent. The
IoT makes our lives easier and better in many
regards, but unfortunately you also have to take
into account that, in the rush to get these devices to market, [manufacturers] forget about security, Honan said. Were seeing IoT devices,
from kettles and light bulbs to a range of different products, that are insecure out-of-the-box;
they have weak security, default passwords... and
can allow people with malicious intent to control
those devices for their own needs.
Honan added, We also have issue on privacy as lot of these devices can take a lot of information, which is being used by companies to
improve services. But if that information falls
into wrong hands, that will impact on privacy.
Attacks aplenty
Ken Munro is the CEO and founder of penetration testing outfit PenTest Partners, which
has found numerous IoT device vulnerabilities
over the last year, and he agreed with Honan
that security must be baked-in to products from
the start, especially given the fast acceleration of
IoT devices.
The reason I love IoT as a security researcher is
that theres enormous attack surface, Munro said,
adding that attackers can leverage everything from
device and mobile application flaws to API and
server infrastructure vulnerabilities to attack IoT
users. He said that rolling such devices out across
staff and customers is simply accentuating that risk.
Munro added, Everyone has got access to
everything with IoT, and this means that you
need firmware, OS, mobile app, and coding
experts... You need to know how to put apps
Were seeing IoT devices, a range of different products,

that are insecure out-of-the-box; they have weak security,
default passwords.
CONTROL ENGINEERING
www.controleng.com
together with wireless or GSM technology.

Theres a massive expansion skillset required in
order to adopt IoT. Were seeing crazy acceleration of IoT devices available, primarily because
theres money to be made, but I think were going
to see standards starting to become available.
Munro is working on standards at the IoT
Security Foundation and says the GSM Association, which focuses on the interests of mobile
operators worldwide, is working on something
similar for mobile communications. Munro
added that vendors are too often focused on
getting goods to market rather than on devices being secure. Some, he said, simply hope to
patch the OTA or Hope the problems go away.
Munro, who praised Fitbit for bolstering
its own security team at the start of the year,
said that IoT flaws, which usually reside in app
source code or resolve around weak passwords
and unsecured Wi-Fi, may enable attackers
to take control of devices locally or remotely.
The latter could ultimately lead to larger-scale
attacks, such as turning off heating or surveilling
a property to see when it is not occupied.
Other experts, meanwhile, have cited patch
management as a major issue given billions of
IoT devices forecast to ship and say that more
elaborate IoT attacks could lead to driverless
cars becoming mobile bombs or connected
devices sending malware via botnets or through
spam emails.
Benefits outweigh the negatives
Shipping company Maersk reportedly has

one of the largest deployments of Industrial
IoT (IIoT), to ensure refrigerated containers all
maintain the correct temperature.
Speaking at a recent conference, Maersk UK
chief intelligence officer (CIO) Andy Jones outlined the benefits of the deployment, saying that
the firm is now able to monitor goods in realtime via IP-enabled sensors, whereas it previously took engineers two days to check and report
on these conditions.
The readings from these sensors are continually fed into Maersks monitoring systems via
satellite, and any problems at sea can be identified immediately. Jones said the problem arises
where IoT systems are connected to something
physical, like braking or airbag systems of vehicles or the heating and cooling systems of buildings. There are many security challenges; not
only because of the difficulty in keeping devices
and software patched but also because the Internet protocol (IP) used by IoT devices is inherently insecure.
www.controleng.com
Risk factors: Internet, devices, users
Combine this with the fact the Internet does

not have any form of service level agreement,
that there are millions of devices in the hands
of unsophisticated users, and that the Internet is
accessible worldwide, and you have the perfect
storm, he said.
Alan Woodward, computing professor at the
University of Surrey, added: My big concern
from a security perspective ... is that IoT is set up
using embedded computing, which is notorious
for cheap, open-source, off-the-shelf bits of software and hardware.
Any risk assessment should include

the criminal mindset and learn from
past analogies.
Woodward is also concerned about cheap

devices and weak patch management, saying on the
latter that updating the firmware on embedded IoT
systems is extremely difficult and problematic.
I think IoT has far more potential than
mainstream computing for being compromised,
he said. The IoT is a classic area where people
are having to relearn all lessons taken 25 years to
learn in computing.
What businesses can do: audits
Munro urged CIOs and other IoT decision

makers to be proactive in auditing and managing devices, even it means walking the floors
to find out what devices are connecting to enterprise networks.
The CIO, he said, must think really seriously what data could be compromised if there is a
system breach, and what hackers have access to
if the network is segregated.
Jones is optimistic about future security
plans, but he advised isolating IoT devices at
risk. Any risk assessment should include the
criminal mindset and learn from past analogies,
he said.
Woodward urged companies to rollout IoT
policies so users clearly know their data can be
wiped and devices managed. ce
Doug Drinkwater is editor at Internet of Business, which is hosting the Internet of Manufacturing Conference Nov. 1-2, 2016, in Chicago.
Internet of Business is a CFE Media content partner. Edited by Joy Chang, CFE Media,
jchang@cfemedia.com.
CONTROL ENGINEERING
MAY 2016
| DE2
Getting ahead of the

IIoT cyber security curve
The Industrial Internet of Things (IIoT) offers many potential benefits, but it also poses many potential
risks from a cyber security standpoint, and many companies are slow to realize this drawback.
MORE
ADVICE
KEY CONCEPTS
The Industrial Internet of Things
(IIoT) can be a major security risk if it
isnt implemented correctly.
Cyber security awareness is higher
than it has ever been and users are
more knowledgeable about potential
risks to their network.
Increased connectivity, data
collection, and intelligence with
things like cloud services presents a
potential security challenge.
GO ONLINE
related topics.
Going to market
CONSIDER THIS
What additional measures should
users take when it comes to the IIoT
and cybersecurity?
DE3
MAY 2016
alking about the Industrial Internet of

Things (IIoT) is at such a fevered pitch
not seen in the industry in a long time,
or if ever, but what users and vendors
alike need to understand is security
needs to be a major part of the discussionand it
appears it is not. The IIoT offers great advantages
if properly implemented, but there is great danger
if implementation is done wrong.
IIoT products are hitting the market at such
a rapid manner it has gotten to the point where
there is a smart anything going out right now. In
the IIoT the hope is users have matured enough to
realize by adding in intelligence and more connectivity there should be added security.
Vendors of the products for mainstream controls companies have spent a lot of time and effort
trying to figure out how to secure their programmable logic controllers (PLCs), distributed control
systems (DCSs) or drives, said security controls
expert Eric Byres. Now we have all these other little things makers and security is not even on their
radar. They are probably good product engineers;
they have a product, and they are making them
an IIoT product by putting in a chip, an Ethernet
interface, and a web server, [and] they say we now
have an IIoT product. In my experience, they say,
security, what security? For security, they say the
client should keep it off the Internet. They take a
product, and try to make it an IIoT product, and
security has not even come into their wheelhouse.
That all falls back on thinking about security
from the outset. In the rush to get to market, no
one is thinking security.
Nobody stopped to think about the impact,
Byres said.
If the marketing hype is to be believed, there has
been a rush to get to market, and that could end up
as an issue within the industry if users dont force
things suppliers to ensure a secure product.
I believe the original intent was to make IIoT
mean it was an industrial system which encompassed reliability and security, amongst other
CONTROL ENGINEERING
things, said Graham Speake, CSO at Berkana

Resources Corp.
While some companies might be designing systems to meet these goals, the drive to get
new and innovative products out the door is
often causing the additional engineering needed to produce a secure solution being shortened
or curtailed altogether. Often the need to be seen
in this (IIoT) space as a leader is more important to companies as they know the sales cycle
can be long, and features (such as security) are
often perceived as being able to be added if the
end user demands them.
That means IIoT right now could be a security
runaway train.
IIoT is something that is being adopted
regardless of security, said Yoni Shohet, chief
executive at SCADAfence. It is being adopted because it saves these industrial companies
money. Whether these architectures or networks
are secure or not is not relevant to decide of they
will adopt or not. They will adopt. The question is
how well will they secure them after they adopt.
The good news is security awareness level is
higher than it has ever been, so a user understands
the talk about securing his or her system at the
plant and over the Internet.
Vendors supply basic security, but it is not
enough. It is also the people and organizations
adopting the products. It needs to be a combination of both. It is about having the right people
and right policies on the job for IIoT security,
Shohet said. We are seeing an increase in IIoT
products that increase productivity regardless
of the level of security. I dont think there are
a lot of companies that will stop an integration
that can save them a lot of money because they
think it is not secure. It is part of an awareness
of potential risk. I think they understand the
risk at a very basic level.
Already there
The interesting thing about the IIoT comes

from all the mini devices that were not intelligent until recently, and security for those devicwww.controleng.com
es is different. They end up using unsecured

protocols. They have a small amount of software, processors, and a tiny amount of memory. If security ends up built-in, then there is no
problem, but if it is not, then there will be cases
where hackers can end up manipulating things
remotely over the Net.
While the IIoT hype has ramped up, the actual technologies behind it have been around the
industry for quite some time as intelligent control devices that have been interconnected. Look
at the smart grid.
The challenge comes when a user ends up
tying all this connectivity, data collection, and
intelligence with things like cloud services, and
this connected network of things that once lived
well within the confines of the companys network, is now a part of the Internet. That means
the attack surface just skyrocketed.
IIoT is in many ways already part of the
industry and has been for the last decade, Byres
said. After all, what are all those RTUs and IEDs
in substations and on utility pole tops if not
Smart, Interconnected Things? What are all
those EtherNet/IP drives and sensors? The big
change/threat is in:
1. The number of new and different things
being integrated, especially from vendors

traditionally separate from the actual
control functionality
2. The scale of the interconnections

3.The attention industry is now getting
from bad actors like the people responsible for the Ukraine blackouts
or Dragonfly.
The IIoT has been part of

industry for the last decade,
but new threats are the
number of new and different
things integrated, the scale
of interconnections, and skill
level of hackers.
All these changes require a different way of

looking at industrial control system (ICS) security, instead of the obsolete bastion model (aka
electronic security perimeter in NERC CIP)
particularly popular in power industry security
regulation today, Byres said. When your security cameras tunnel through your firewalls to
connect to a site in China, it has to be 100% certain your control network is not ever connected
to the Internet. ce
Gregory Hale is the editor and founder of Industrial Safety and Security Source (ISSSource.com),
a news and information website covering safety
and security issues in the manufacturing automation sector. ISSSource is a CFE Media content
partner. Edited by Chris Vavra, production editor, CFE Media, Control Engineering,
ControlEngineeringTV on YouTube
Visit Control Engineering on YouTube to watch videos on demonstrations and
tutorials on subjects ranging from cyber security to thermocouples as well as the
latest press events. Here are some of our most popular videos on YouTube:
Thermocouple Tutorial
Video tutorial: Differential pressure flowmeters
Tutorial: Measuring liquid level using a bubbler
Dual Arm Concept Robot (DACR)
To see more videos and to subscribe to ControlEngTV visit
www.youtube.com/user/ControlEngineeringTV
CONTROL ENGINEERING
MAY 2016
| DE4
Financial benefits of combining

automation and safety projects
Collaborating on seemingly disparate projects could help companies save money by having the
different departments focus on areas where their interests and agendas overlap.
lmost every mid- to large-sized manufacturer has dedicated engineering

and environment, health, and safety (EH&S) departments. Because
the purpose, goals, and objectives of
these departments have traditionally had very little overlap, its not too uncommon to find these
departments working with no knowledge of what
the other is doing. Engineers constantly work with
operations to find new ways to improve productivity and efficiency. Safety professionals are assessing,
reducing, and managing risks while juggling regulatory requirements. So its not a big surprise that
these two departments rarely cross paths throughout a given year. As more advanced technologies
continue to hit the marketplace, especially technologies designed to provide a safer and more productive work environment, the importance of cross
functional collaboration between these departments
becomes critical for survival.
Many companies dont realize how much money
the company could be saving by collaborating, even
on seemingly disparate projects. One of the biggest
areas of financial impact for collaboration between
EH&S and engineering can be on everyday proj-
ects that involve machinery and equipment. Chances are projects involving machinery and processes
consume a majority of the companys capital budgets. Not collaborating could be costing the company money when it isnt necessary.
Until recently, the primary method to reducing risk was to add physical guards to equipment
to prevent employee access to hazardous conditions.
Over the years, the industry has slowly progressed
into developing risk reduction measures, which
has allowed easier access to equipment by replacing the physical guards with intelligent safeguarding devices. These devices were typically connected
to a single-purpose, safety-rated logic device that is
independent of the machines control system to create a dedicated safety system. At the time these safety devices and systems were being installed, it really
was the only cost-effective option available. However, with safety measures being integrated into
standard automation devices, there are financial
incentives for EH&S and engineering to collaborate
on corporate strategies and future capital projects.
Collaboration case study
To determine the true savings of collaboration, a
MORE
ADVICE
KEY CONCEPTS
Upgrading controls systems can
save companies more money over the
long term.
Operations should work with the
engineering department for better collaboration and long-term, cost-saving
initiatives.
GO ONLINE
Links to related articles appear
with the online version of this article.
Click on the headline to see that.
CONSIDER THIS
Could a lack of collaboration be
costing your company unnecessary
money loss?
DE5
MAY 2016
CONTROL ENGINEERING
Figure 1: The image shows

the project design overviews
before implementation. All
tables and figures courtesy:
Grantek
www.controleng.com
Table 1: Separate projects, both depalletizers
case study was conducted by reviewing two different project proposals at a large food and beverage
company. The project proposal requests occurred
within a six-month span of each other and happened to be on the same pair of 15-year-old depalletizers. The purpose of the project was to upgrade
the safeguarding and safety systems on both depalletizers. The driving factor for this project was the
occurrence of a recent serious injury and the awareness that the current safeguarding measures were
insufficient. Since the scope of this project was only
upgrading the safety-related aspects of the machine,
a secondary control panel was needed to add the
additional safety control components (see Figure
1). The scope of the second project was to upgrade
the original (and now obsolete) control system and
the operator station with a new programmable logic
controller (PLC) and modern human-machine
interface (HMI).
Table 1 shows the cost breakdown of each
respective project as it was originally proposed.
Cost analysis 1: Combining projects
The first cost analysis exercise was to explore the

potential savings of combining these two independent projects into one project. In developing a new
proposal to reflect the anticipated savings, it was
assumed that the scope and engineering solution
of each project would remain exactly the same. By
keeping the solutions the same, it was easy to determine the added costs associated with keeping these
projects separate. Table 2 shows that roughly combining these projects to take place at the same time
would save $45,000.
Many factors were determined in coming up
with the calculations for the combined project
in Table 2, but a few of the noteworthy discoveries were:
Project management savings (30%) were
achieved through a reduction in mobilization time
(project understanding, kick-off meetings, information gathering, etc.) and management time
(scheduling, financial monitoring, etc.).
System integration savings (40%) were
achieved through a reduction in duplicate software programming efforts that were mainly
comprised of eliminating unnecessary code modifications on the safety project to communicate
with the original PLC.
Electrical design savings (35%) were achieved
through a reduction in schematic modification and development time. The safety project
required modification of 12/15 existing drawings with the addition of 14 new drawings. The
PLC project would have required modification
of 15/15 drawings with the addition of only four
new drawings instead of 14.
www.controleng.com
Safety upgrade
PLC upgrade with HMI
Project management
$7,130
$5,060
System integration (software)
$13,040
$18,400
Electrical design
$30,520
$20,240
Mechanical design
$4,800
Electrical hardware
$46,064
Mechanical hardware
$40,000
$0
Installation (electrical, mechanical)
$40,000
$9,000
Commissioning, startup support
$23,080
$15,640
Total
$204,634
$99,294
$0
$30,954
SUM $303,928
Table 1: This table displays the cost breakdown for independent projects.
Table 2: Costs of combined projects, savings

Combined project cost
Project management
Savings
$8,533
30%
$18,864
40%
Electrical design
$32,994
35%
Mechanical design
$4,800
Electrical hardware
$77,018
Mechanical hardware
$40,000
$46,550
5%
$29,040
25%
Totals
$257,799
15.2%
Table 2: This table shows the cost of projects if done together, with
15.2%, $46,129, savings compared to the sum of the columns in Table 1.
Table 3: Re-engineering combined projects adds more savings

Re-engineered totals
Project management
$8,533
$18,864
Electrical design
$32,194 (2% less, $800 more savings)
Mechanical design
$4,800
Electrical hardware
$76,018 (1% less, or $1,000 more savings)
Mechanical hardware
$40,000
$36,550 (21% less or $10,000 more savings
$29,440
Total project cost, re-engineered
$245,999 (19.1% total savings, $57,929)
Table 3: Re-engineering combined projects creates extra savings of $11,800, in

three (bold) of eight areas, for $57,929 total savings, or 19.1%, less than Table 1.
Table 4: Project change orders add costs
Functional modification requiring

design change of
safety system
Number
of change
orders performed
(out of 84
machines)
Average
cost per
change
order
with nonintegrated
solution
Average anticipated cost per

change order
with an integrated solution
Overall
project savings with an
integrated
solution
51
$8,500
$5,000
$178,500
Table 4: Project change orders can add significantly to overall project costs.
CONTROL ENGINEERING
MAY 2016
| DE6
Figure 2: This image

shows the schematic for
the re-engineered safety
and PLC solution.
Commissioning and start-up savings (25%)

were achieved through reduction in duplicated site
acceptance testing, I/O checks, system debugging,
and travel/expense time.
solution such as downtime reduction and reduced

exposure to hazards. Most of these benefits are well
advertised by all the hardware manufacturers. What
is often not addressed as part of an integrated safety
solution is the cost associated with making modifications (either change orders to the existing project
requirements or future changes) to the system. On
a small project like the one mentioned earlier, the
changes may not be as noticeable.
However, when a company is tackling a largerscale safety or control project, these costs can add
up. Table 3 shows the anticipated cost savings on a
larger project associated with change order requests
when utilizing an integrated safety solution. The
project for this evaluation consisted of 84 packaging machines with a total of 51 change orders
throughout the entire project (ranging from simple
programming tweaks to in-depth functional changes). As high as this number of change orders may
sound, its on par with typical large-scale, multiplant projects. With an integrated safety solution, a
majority of these requested changes are now capable of being accomplished through programming,
as opposed to physical changes, to the hardware.
On average this reduces costs by about $3,500 per
change order (averaged out over the 84 machines).
Cost analysis 2: Re-engineering projects
Financial benefits
When any engineering-related projects are

combined into one single project, there are potentially additional cost savings options available
through alternative solutions. Engineers are no
longer restricted to focusing on independent solutions which serve a single purpose. Instead, they
are able to re-engineer solutions to be streamlined
and simplified. For example, if the machines PLC is
being replaced as part of the upgrade, there would
be no need to add a secondary control panel to support a dedicated safety control system. Why not just
use a safety PLC to simplify the engineering and
design efforts? Expanding on the first cost-analysis
exercise, an additional proposal was developed to
reflect a re-engineered solution (see Figure 2) to
accommodate a simplified solution.
The single, biggest advantage of using an integrated safety solution from a project perspective
would be installation time. The new solution avoids
having a dedicated safety controller in a separate
panel, which provides a simpler, cleaner installation.
A safety PLC is more expensive than a standard
PLC and separate safety controller, but the overall
solution costs less to implement. Overall hardware
costs, electrical design costs, system integration and
wiring costs, and on-site labor costs are less.
Operational benefits
There are myriad day-to-day and long-term

operational benefits from using an integrated safety
DE7
MAY 2016
CONTROL ENGINEERING
In any given year Grantek performs around 300

to 500 controls systems upgrades and around 50 to
75 safety upgrades. Only around 5% of these projects address both upgrades at the same time. This
shows that most companies are not considering the
cost benefits of considering both projects. There are
instances, however, when there is no advantage to
combining these projects. For example, there are
safety upgrades that are mechanical in nature and
require little to no safety controls.
On the flip side, the savings can grow even further when technologies are combined as part of
the solution. For example, servos and variable frequency drives (VFDs) now have built-in safety
capabilities, and in this case, it may be worth considering evaluating the upgrade of motion components when addressing either controls- or
safety-related projects.
The lines between automation and safety are
becoming more blurred, especially in recent years.
Dont fall in the trap of missing opportunities to
save money by continuing to keep these two technologies and disciplines separated. ce
Jeff Winter is the director of safety practice at

Grantek Systems Integration, edited by Mark T.
Hoske, content manager, Control Engineering,
mhoske@cfemedia.com. This longer version of an
article, with additional graphics, appeared among
the cover story series of articles in April.
www.controleng.com
eNewsletters
Control Engineering covers relevant topical articles in a variety of

eNewsletters each and every month:
CEs Top 5 Reader Favorites
Energy Automation
IIoT Report
Industrial Networking
Industry News & Products
Automotive & Transportation
Chemical Manufacturing
Packaging
Information Control
Machine Control
New Products for Engineers Showcase
Planning and Design
Process & Advanced Control
Process Instrumentation & Sensors
Safety & Cybery Security
System Integration
Whitepaper Connection
Subscribe today by visiting
Products For Engineers
PE
Control Systems
SHOWCASE
Process Manufacturing
Discrete Manufacturing
System Integration
Netwroking & Security
Info Management
Wednesday, October 22, 2015

One Chip. One Company. All Your Network
Solutions.
The netX network controller chip
family from Hilscher integrates
fieldbus and industrial Ethernets
for transparent protocol
conversion. One chip, 12 networks,
24 protocol stacks. All stacks have
the same Driver Interface. Master
stacks include FDT-based
Configuration Tool.
Register to learn more.

Solutions.
Solutions Direct offers discounted
prices on over 8,000 Electrical
Enclosures and Thermal
Management Products. Sizes range
from 2 x 2 to 86 x 187 and meet
NEMA/UL Ratings.
Click to learn more.
On-demand webcasts
It's never been easier to earn
continuing education credits! Attend
our 1-hour-long webcasts now
available on-demand.
Learn More.
Kepware Releases KEPServerEX V5.16

with New Local Historian Plug-In
The plug-in captures data at the
source to prevent data loss and
improve operational efficiency with
an easy to configure, flexible, open,
and cost-effective solution.
Download a free Demo.
Engineers' Choice Awards finalists

Official Engineers Choice ballots are
open for voting for Control
Engineering North American print
and digital edition qualified
subscribers. Based on your
experience, vote for the best
Engineers Choice finalists of 94
products in 26 categories.
Vote Now!

Solutions.
The netX network controller chip
family from Hilscher integrates
fieldbus and industrial Ethernets
for transparent protocol
conversion. One chip, 12 networks,
24 protocol stacks. All stacks have
the same Driver Interface. Master
stacks include FDT-based
Configuration Tool.
Register to learn more.
MEDIA SHOWCASE FOR ENGINEERS

Your place for new products, literature, Apps, Videos, Case Studies and White Papers.
ISO5167 Multivariable
Mass Flow Computer
North
Serving Northeast and

Central Regions
Mass flow measurement under
ISO5167 standard for orifice plates,
nozzles and venturi tubes.
Arian Flow Cad software with fluid
physical properties based on:
NIST Standard Reference Database,
IAPWS-IF97, AGA 8 DC92.
Reliable in tough environments.
more information:
www.arian.cl/flow
Ask About Our

InTouch HMI
Contact us for all your challenging HMI,
SCADA and Automation projects.
Expert Assistance and Support
Award Winning Technical Support Team
Application Assistance and Best Practices
Advanced Application Expertise
Over 25 Years Helping Customers Succeed
Web: wonderwarenorth.com
Email: sales@wonderwarenorth.com
Phone: 877-900-4996
Input #100 at controlengineering.hotims.com
eNewsletters
ad2_10.indd 1
2/12/2016
5:51:14 AM
AIS North-CE0-042816.indd
1
4/28/16 10:04 AM
Control Engineering covers relevant topical articles in

a variety of eNewsletters each and every month:
CEs Top 5 Reader Favorites

Energy Automation
IIoT Report
Industrial Networking
Industry News & Products
Automotive & Transportation
Chemical Manufacturing
Packaging
Information Control
Machine Control
New Products for Engineers Showcase
Planning and Design
Process & Advanced Control
Process Instrumentation & Sensors
Safety & Cybery Security
System Integration
Whitepaper Connection
stay
informed
Stay current
with technology and
trends in electrical,
mechanical,
instrumentation
and automation.
Subscribe today by visiting
subscribe, visit
Input #105To
at controlengineering.hotims.com
www.controleng.com/subscribe
58
MAY 2016
CONTROL ENGINEERING
www.controleng.com
MEDIA SHOWCASE FOR ENGINEERS

Your place for new products, literature, Apps, Videos, Case Studies and White Papers.
INCREDIBLY
FASTER!
CORD DROP
DISCONNECT SWITCHING
The USB 3 uEye CP with

ON Semiconductor CMOS
sensors
Loop Powered 4...20ma

Isolating Conditioners
SIMPLIFY DESIGN & STARTUP

Switch-rated plugs and receptacles
are ideal for cord drop applications.
Technicians can easily deenergize
equipment without having to wear
cumbersome PPE and without
having to climb a ladder to
disconnect power.
OFF Button
Provides push button

circuit disconnection
Safe and reliable inputs for PLCs.

Protects from surge voltages and
eliminates ground potential
differences.
4kV and 10kV isolation.
5 years guarantee.
Safety Shutter
Simplifies NFPA
70E compliance
www.ids-imaging.com/usb3
distributors wanted, more information:

www.arian.cl/din
UL Switch-Rated:
Up to 200A,
75hp, 600V
meltric.com
800.433.7642
Want to receive your

Control Engineering
magazine as a
control-engineering-usb3-ueye-cp-on-semis-sixth-page-2016-04.indd
19.04.20161 13:05:24
II o T
ad4-2.indd 1
MQTT Protocol

2/12/2015 7:03:37 AM
Flexible Temperature
Sensor Saves Time
and Money
digital publication?
Maple HMIs: Your Gateway to the IIoT
Information is Power.
Maple Systems edge gateway
HMIs utilize MQTT protocol to
unlock valuable data from existing
machine processes. Monetize that
data today using the power of
information technology.
technolog Achieve
better access to data and increase
Update your subscription,

and get our digital edition,
on a more interactive and
user-friendly platform,
in your email in-box.
Update now at:
www.controleng.com
www.controleng.com
your companys bottom line by

joining the IIoT with Maple Systems.
The WORM, an innovative exible

sensor, installs in minutes into most
thermowells. It bends and slides
right in without having to remove
the transmitter enclosure or
assembly components.
Watch the video

www.miinet.com/TheWORM
or call 800-999-2900
Connect your machines today.
Your Industrial Control Solution

www.maplesystems.com | 425.745.3229
Demand Moore Reliability

CONTROL ENGINEERING
MAY 2016
| 59
ControlEng_2015-06_WORM_MediaShowcase2x4_MII.pd
Need a System Integrator?

Automation & Control Concepts
SYSTEM INTEGRATION EXCELLENCE
These are just two of many service providers in

the Global System Integrator Database.
Find a System Integrator for your project today!
To search the Global System Integrator

Database, or to create your own System
Integrator Corporate Profile visit
www.controleng.com/global-si-database
ACC is a St. Louis-based

systems integration firm
that focuses on client
satisfaction through
excellence, innovation
integrity and attention to
detail.
ACC has a record of
retaining satisfied
customers, as over 90%
of our new work is repeat
business.
ACC is one of the most
recognized Systems
Integrators in the Midwest
for their GE Intelligent
Platforms, Wonderware,
Rockwell Automation,
TracKSYS, LineView and
Modicon Systems
Integration Capabilities.
100 N Broadway
Saint Louis, MO 63102
Email: hr@a-cc.com
Website: www.a-cc.com
Primary Industries
Food & Beverage
Solar Renewable Energy
Packaging Optimization
Huffman Engineering, Inc.
HUFFMAN ENGINEERING, INC. PROVIDES PROFESSIONAL AND

CUSTOM SOLUTIONS TO REGULATED INDUSTRIES
Howard Huffman, President

Huffman Engineering, Inc.
5301 North 57th Street
Lincoln, NE 68507
Telephone: (402) 464-6823
Fax: (402) 464-6892
Email: info@huffmaneng.com
Website: www.huffmaneng.com
Primary Industries
Food
Life Sciences
Pharmaceutical
Utilities
Water/Wastewater
Innovative. Professional. Knowledgeable. Thorough. This

is how Huffman Engineering, Inc.s customers describe
the work we do. Our complete approach to systems
integration includes understanding customer processes,
designing systems to meet process needs, and implementing the right system to improve production.
We have provided quality engineered systems and services to industrial, manufacturing, and utility customers,
with an emphasis on regulated industries since 1987. At
Huffman Engineering, our degreed and licensed engineers and technicians approach every control integration
project with the customer in mind.
Our thorough and professional care with each project involves listening carefully to customer needs,
developing a plan, and following through with execution, testing, and documentation. Huffman Engineerings extensive background with regulated industries, such as pharmaceuticals and utilities, means we
understand the requirements and documentation necessary to complete projects successfully. Our experience across multiple manufacturers with various customer processes ensures that we are innovative and
creative in delivering the most beneficial solution.
Huffman Engineering is CSIA certified, a Rockwell Process Integrator, a Wonderware Certified Systems
Integrator, and has been written into multiple specifications as a single source integrator. A recognized
leader in Control Systems Integration in the Midwest, Huffman Engineering is the choice for customers
seeking value.
Full Profile at www.cfemedia.com/global-si-database/HuffmanEngineering
NEW PRODUCTS and software

See more products daily at www.controleng.com/products.
Coriolis transmitter with Ethernet connectivity
Safety diagnostics system

for collecting sensor data
Pilzs Safety Device Diagnostics system is comprised of a fieldbus module,
junction, and safe sensor technology.
The diagnostic system is designed to
enable a wide range of sensor data to be
called up including over distance. Service
operations can be reduced and increase
productivity as a result. Safety Device
Diagnostics also provide data such as
partial operation, voltage spikes and dips,
temperature effects, switching cycles,
bounce, and RFID identification as diagnostic information. The integrated display on the fieldbus module also ensures
that information is available not only on
machine monitors but also directly in the
control cabinet. Third-party devices also
can be connected directly via the integrated input and outputs (I/Os).
Pilz,
www.pilz.us
Input #200 at www.controleng.com/information
Emerson Process Managements Micro Motion Model 5700

transmitter has been upgraded with a native Ethernet connection designed to improve connectivity and functionality for
easier access to measurement information. The native Ethernet
upgrade includes dual redundant Ethernet ports, directly integrated
in the device with no need for extra converters or adapters. The dual
port architecture means multiple devices can be installed in a variety
of configurations, minimizing wiring and switch needs for space and
cost savings. The transmitter also incorporates a configurable I/O
channel that can be used as a discrete input or set to a mA, frequency, or
discrete output. This enables powerful application options with minimal equipment.
Emerson Process Management,
www.emersonprocess.com
Cartesian robot system for motion profiles

Rollon Corp. Motion Box is a pre-engineered Cartesian robot system designed to deliver to users six motion profiles that can be set
up and running in a few hours. Motion Box covers everything from
the human-machine interface (HMI) on one side to the output of reliable motion on the other end. The initial system
setup is already complete so end users can get parts moving in a repeatable manner. Motion Box has six pre-programmed motion profiles to suit more than 80% of all
Cartesian motion applications. Motion Box also offers
flexible integration options via an Ethernet connection
as well as wider automation setups using EtherNet/IP,
DeviceNet, TCP/IP, CC-Link, Profibus and Profinet, as
well as company networks and control architectures.
Rollon Corp.,
www.rollon.com
Software upgrade for modeling and simulation platform

Maplesofts upgraded modeling and simulation platform, MapleSim 2016, features additions that include interface changes to improve workflow, expanded component libraries, and extensions to toolchain connectivity. These improvements
include task panels that appear automatically as needed and then disappear again to
maximize model workspace, redesigned layout that ensures tools are readily available at the moment they are needed, and a new search bar that provides one point
of access for searching help pages, component libraries, examples, attachments, templates, and models from the MapleSim Model
Gallery. MapleSim 2016 also includes an expanded multibody component library to support contact modeling, which covers a
variety of surface shapes and enables engineers to quickly model contact between different objects in their model.
Maplesoft,
www.maplesoft.com
Process viscosity analyzer for measurement applications

PACs ViscoSure is a process viscosity analyzer that combines oscillating piston technology with tight
temperature control to provide precise viscosity analysis. With internal temperature control without
using the traditional external oil bath, the ViscoSure requires little to no maintenance. Its measurements
allow for precise and continuous adjustment while maintaining a high correlation with ASTM D7483 and
ASTM D445 test methods. Performance, reliability, and precision are critical for viscosity measurements
in bottom of the tower applications. ViscoSure is designed specifically for asphalt, heavy fuel oil, and lubrication oil applications. It also features a sample conditioning system (SCS), which is designed to optimize
the instruments performance and protect the analyzer from process disruptions, which reduces downtime.
PAC, www.paclp.com
www.controleng.com
CONTROL ENGINEERING
MAY 2016
| 61
NEW PRODUCTS and software

See more products daily at www.controleng.com/products.
Brushless dc motors for smooth running applications

Nanotecs DB41 and DB43 brushless dc (BLDC) motors are designed for applications that require
smooth running characteristics and a long service life. The 10-pole DB41 has low nominal speed,
which makes it useful for applications with mid-range speeds up to 3,000 rpm. It is equipped with
bonded magnets as well as hall sensors that report back the rotor position. The peak output of these
NEMA 17 motors ranges from 66 to 339 W and has a nominal torque from 0.07 to 0.36 Nm. The
DB43 model series has six poles and sintered magnets and is available with hall sensors or a magnetic encoder and safety brake. The DB43 has a peak output of 159 to 414 W and a nominal torque
of 0.17 to 0.44 Nm. Its operating voltages range from 24 to 48 V.
Nanotec,
us.nanotec.com
Temperature control system series

for heating, chilling cycles
Mokons Full Range temperature control system combines a circulating water system and an iceman chiller to
provide heating and chilling from a compact, self-supporting unit. It can be used for industries and processes that require heating and chilling cycles. It has standard
heating capacities up to 96 kW, pumping capacities up to
120 GPM, chilling capacity up to 40 tons,
and temperature range of -20 to 300 F (-29
to 149 C). It has stainless steel centrifugal
pumps, a microprocessor-based controller
with an LED readout, and a NEMA-rated
electrical enclosure with safety disconnect
switch.
Mokon,
www.mokon.com
Linear motion platform

for scanning, machining
applications
Griffin Motions high-speed LM3
Series 300 mm-travel precision linear
motion platform is designed for inspection, scanning,
optical positioning, and laser marking and machining applications. These compact, low-profile linear motor stages exhibit
strong levels of accuracy (15 m), repeatability (1 m), flatness (5
m), and straightness (5 m) with regard to travel and attain high
linear velocities up to 900 mm/s. This makes them useful for factory automation and semiconductor processing equipment. Additional features of the LM3 Series 300 mm-travel precision linear
motion stages include ironless linear servomotors and recirculating
ball linear ways, which enable smooth motion and velocity control.
Griffin Motion,
www.griffinmotion.com
PRODUCT & LITERATURE SHOWCASE

5B / 7B / 8B Signal Conditioning Solutions
More Models, More Protection, Less Noise, Lower Cost

580+ different 5B, 7B, and 8B signal conditioners provide accurate, isolated Instrument
Class performance to ensure the integrity of your industrial automation, data acquisition,
process control, and quality assurance systems. Custom modules available.
0.03 to 0.05% Accuracy
ANSI/IEEE C37.90.1 Transient Protection
1500Vrms Isolation
3- to 6-Pole Low-Pass Filtering
Up to 240Vrms Input Protection
-40C to +85C Operating Temperature

CSA C/US Certified & ATEX Compliant
(5B, 7B)
Acromag Signal Conditioners & Ethernet I/O

We have the experience
to help improve reliability,
increase productivity, &
reduce your costs.
Get your new product guide today.
4-20mA Isolators and Splitters
Ethernet, Modbus, Profibus Remote I/O
877-295-7057 www.acromag.com/ce
C-UL-US Listed (8B)
Call 800-444-7644 or visit www.dataforth.com

Place your Classified, Literature

Showcase or Product Mart ads today!
Contact: Iris Seibert at 858-270-3753 or ISeibert@CFEMedia.com
Go online to view the weekly

Top 5 Reader Favorites!
www.controleng.com
62
MAY 2016
CONTROL ENGINEERING
Advertising Sales Offices

ContentStream
Patrick Lynch,
Director of Content Marketing Solutions
630-571-4070 x2210
PLynch@CFEMedia.com
AL, FL, GA, MI, TN
ad index
Company
Page#
RSN
Web
ABB Drives and Controls . . . . . . . .17 . . . . . . . . . . 10 . . . . .www.abb.com/drives

Advantech Corporation . . . . . . . . .12, 13 . . . . . . . . 8. . . . . .www.advantech.com
Allied Electronics . . . . . . . . . . . . . .7 . . . . . . . . . . . . 5. . . . . .www.alliedelec.com
AutomationDirect . . . . . . . . . . . . . .C2 . . . . . . . . . . . 1. . . . . .www.automationdirect.com
Beckhoff Automation LLC. . . . . . . .33 . . . . . . . . . . 15 . . . . .www.beckhoff.com
Carlo Gavazzi, Inc . . . . . . . . . . . . . .35 . . . . . . . . . . 16 . . . . .www.GavazziOnline.com
Control Engineering Webcasts. . . .11 . . . . . . . . . . . . . . . . . .www.controleng.com/webcasts
EZAutomation . . . . . . . . . . . . . . . . .Bellyband . . . . . . . . . . .www.EZAutomation.net
FORCAM . . . . . . . . . . . . . . . . . . . . .46 . . . . . . . . . . 20 . . . . .www.forcam.com
Global System Integrator
Database Featured Integrators . . .60 . . . . . . . . . . . . . . . . . .www.controleng.com/global-si-database
Honeywell Inc . . . . . . . . . . . . . . . . .10, 27 . . . . . . .7, 12 . . . .www.honeywellprocess.com/experion
Kepware Technologies . . . . . . . . . .1 . . . . . . . . . . . . 2. . . . . .www.KEPWARE.COM
LINEAR TECHNOLOGY . . . . . . . . . .9 . . . . . . . . . . . . 6. . . . . .www.linear.com/dust
MASSA . . . . . . . . . . . . . . . . . . . . . .30, 31 . . . . . . . 14 . . . . .www.massa.com
Moore Industries - Intl. Inc . . . . . . .4 . . . . . . . . . . . . 4. . . . . .www.miinet.com
Moxa Technologies . . . . . . . . . . . . .3 . . . . . . . . . . . . 3. . . . . .www.moxa.com
Red Lion Controls . . . . . . . . . . . . . .28 . . . . . . . . . . 13 . . . . .www.redlion.net/IIoT
Rittal Corporation . . . . . . . . . . . . . .38, 39 . . . . . . . 18 . . . . .www.rittal-corp.com
SEW-EURODRIVE, Inc. . . . . . . . . . .C4 . . . . . . . . . . 29 . . . . .www.seweurodrive.com
Siemens. . . . . . . . . . . . . . . . . . . . . .C1, 21, 40 . . . 11, 19 . . . .www.sea.siemens.com
SICK . . . . . . . . . . . . . . . . . . . . . . . . .15 . . . . . . . . . . . 9. . . . . .www.sickusa.com
TRACO POWER . . . . . . . . . . . . . . . .37 . . . . . . . . . . 17 . . . . .www.tracopower.com
Yaskawa America, Inc. . . . . . . . . . .C3 . . . . . . . . . . 28 . . . . .www.yaskawa.com
Inside Process
Allied Moulded Products, Inc. . . . .P4 . . . . . . . . . . 22 . . . . .www.alliedmoulded.com
American Industrial
Systems (AIS) . . . . . . . . . . . . . . . . .P3 . . . . . . . . . . 21 . . . . .www.aispro.com
Emerson Process Management. . .P5 . . . . . . . . . . 23 . . . . .www.emersonprocess.comw/operationsperformance
Load Controls Inc.. . . . . . . . . . . . . .P6 . . . . . . . . . . 24 . . . . .WWW.LOADCONTROLS.COM
Maple Systems Inc . . . . . . . . . . . . .P9 . . . . . . . . . . 26 . . . . .www.maplesystems.com
WAGO Corp. . . . . . . . . . . . . . . . . . .P7 . . . . . . . . . . 25 . . . . .www.wago.us
Winsted Corporation . . . . . . . . . . .P10 . . . . . . . . . 27 . . . . .www.winsted.com
REQUEST MORE INFORMATION about products and advertisers in this issue by using
the http://controleng.com/information link and reader service number located near each.
If youre reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Control Engineering.
www.controleng.com
CONTROL ENGINEERING
Maggie Hatcher,
Classified, Product Mart,
Media Showcase
630-571-4070, x2221
MHatcher@CFEMedia.com
AR, IL, IN, IA, KS, KY, LA, MN, MO,
MS, NE, ND, OK, OH, SD, TX, WI,
Central Canada
Bailey Rice
(630) 571-4070 x2206
BRice@CFEMedia.com
AK, AZ, CA, CO, HI, ID, MT,
NV, NM, OR, UT, WA, WY,
Western Canada
Iris Seibert
(858) 270-3753
ISeibert@CFEMedia.com
CT, DE, MD, ME, MA, NC,
NH, NY, NJ, PA, RI, SC, VA,
VT, WV, DC, Eastern Canada
Julie Timbol
(978) 929-9495
JTimbol@CFEMedia.com
CFE Media Contributor

Guidelines Overview
Content For Engineers. Thats what CFE
Media stands for, and what CFE Media is all
about engineers sharing with their peers.
We welcome content submissions for all
interested parties in engineering. We will use
those materials online, on our website, in
print and in newsletters to keep engineers
informed about the products, solutions and
industry trends.
www.controleng.com/contribute explains
how to submit press releases, products,
images and graphics, bylined feature articles,
case studies, white papers, and other media.
* Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other
products or organizations will be rejected.
(Technology discussions and comparative
tables may be accepted if non-promotional
and if contributor corroborates information
with sources cited.)
* If the content meets criteria noted in
guidelines, expect to see it first on our Websites. Content for our e-newsletters comes
from content already available on our Websites. All content for print also will be online.
All content that appears in our print magazines will appear as space permits, and we
will indicate in print if more content from that
article is available online.
* Deadlines for feature articles intended for
the print magazines are at least two months in
advance of the publication date. Again, it is best
to discuss all feature articles with the appropriate content manager prior to submission.
Learn more at:
www.controleng.com/contribute
MAY 2016
| 63
BACK TO BASICS power and grounding
Control system power and grounding

forensic exam aids reliability
Before replacing an aging control system, the engineer willing to conduct a forensic examination
increases the odds the new system will perform reliably. See power and grounding tips.
Industrial automation and control technol-
Young
engineers
may be in the
right place at
the right time
to be part
of a major
control system
replacement
project.
MORE
ADVICE
KEY CONCEPTS
Many control systems are out of
date and in need of a replacement.
Engineers should perform a forensic
investigation to determine what kind
of control system should be installed.
Forensic investigations might be
uncharted territory for engineers, and
recruiting someone to assist can help.
GO ONLINE
more about grounding and control
system replacements, and a link to
get the book: Control System Power
and Grounding Better Practices.
CONSIDER THIS
Forensic examinations can be used
for other engineering projects.
64
MAY 2016
ogies dont operate reliably for several decades

by accident. Those persons willing to learn
the secrets behind that reliability can ensure
replacement systems perform equally well. This
includes appropriate power and grounding.
With new cellphones, tablets, and computer
platforms being introduced every few months,
its understandable to think that discussions
about 15-, 20-, and even 25-year-old technologies is anything more than a history lesson.
While that may be true about the technologies we personally use, things move a bit slower
when it comes to industrial technologies.
In fact, its not uncommon for young engineers at their first job to encounter industrial control systems named Provox (from Fisher,
now Emerson), TDC2000 (Honeywell), IA (Foxboro, then Invensys, now Schneider Electric),
RS3 (Rosemount, now Emerson), INFI90 (Bailey, now ABB), etc. Many of these systems could
be older than the young engineer tasked with
replacing them.
The upside is that young engineers may be
in the right place at the right time to be part
of a major control system replacement project,
which likely appeals to the technology geek for
most. Before ripping and slashing that existing
system however, an engineer should do a forensic investigation of the existing system, which
will prove invaluable when it comes time to
engineering its replacement.
Best-practices power and grounding
Hopefully, the forensic investigation will

reveal that the installed systems power is optically or inductively isolated; grounded to a
single point also known as a star ground (a
design that minimizes ground loops); and there
is proper separation of different cable types.
Engineers willing to do such a forensic examination might find the project daunting because
it isnt the kind of thing that is generally taught
in college. And if it were taught, it might not
have seemed important or relevant at the time.
Short of heading back to school and taking
some electrical engineering classes, the compa-
CONTROL ENGINEERING
ny could hire an electrical contractor or control

system vendor to conduct the forensic examination and prepare as-built documentation, but
thats generally a tough sell to management. A
more palatable solution is to do some research
through books and other sources and compare
the installed system with the descriptions and
diagrams found through research.
Because time and costs are a factor, a forensic examination project might be turned over to
a couple of co-op students or summer interns.
The engineer can supervise while the interns
document whats right and wrong about the
power and grounding of the installed system.
Grounding tips for controls
Control system power and grounding tips include:
1.
Control system ac power should be

supplied from a distribution system
separate from other equipment and uses.
2. The power source should be designed
to accommodate initial inrush currents

that can last up to 10 cycles.
3. Control system ac power should be sup-
plied through an isolation transformer or

uninterruptible power supply (UPS).
4.
Control system ac ground should be

established at or near the isolation
transformer or UPS.
5. Control system workstation ac power
should be routed to a dedicated receptacle.
ce
Dave Harrold is one of the authors of Control System Power and Grounding Better Practices. Harrold retired in 2009 after working for nearly four
decades in the controls and instrumentation industry, including as a Control Engineering editor. Edited by Chris Vavra, production editor, CFE Media,
Control Engineering, cvavra@cfemedia.com.
www.controleng.com
ONE FOR
ALL
Robots, Servos & Drives,

now Controlled by ONE SOFTWARE
Yaskawa introduces Singular ControlTM: robotics,
servo systems and variable speed drives working
together under one software package. Singular
Control uses the same ladder logic youve used for
years, allowing you to develop new automation
without the need for a robot programmer.
Pick, pack and palletize with new programming
power, superior speed and industry-leading
effectiveness, thanks to an innovation that puts
Yaskawa performance and reliability into more
innovative automation designs than ever before.
For more info:

http://budurl.me/YAI897
YASKAWA AMERICA
DRIVES & MOTION DIVISION
YASKAWA.COM
1-800-YASKAWA
Size matters.
Especially with gearmotors...
Too small = premature failure
Too large = high cost & low efficiency
Unsure of your drive size? Then go
online to PT Pilot. Simply enter the
parameters of your hoist, conveyor, or
travel car. PT Pilot will automatically
calculate the optimal horsepower, speed,
and gear unit with or without a VFD.
PT Pilot also provides documentation,
pricing, and a 3D CAD drawing for every
selection. Visit ptpilot.com.
ptpilot.com | 864-439-7537

ControlEng MAY2016

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ControlEng MAY2016

Uploaded by

Copyright:

Available Formats

Sm

Get BIG DATA and BIG SAVINGS...

(Development only package)

Connect to any SQL database (MS SQL,

Optimized Trend History:

Three software packages are available in

Designed to load millions of values

Complete Package - Development + Runtime

Powerful scripting including VBScript

Development Package - Development Only

Get more than you paid for: www.automationdirect.com/point-of-view

Order Today, Ships Today!

the #1 value in automation

Introduce real-time industrial data to your cloud-based business

Kepware Technologies provides a portfolio of software solutions

Expected change to 2016

Increase more than 6%

Stay the same

COVER: Control Engineering Salary Survey graphic, upper

Cover story: Control Engineering research shows salary increases,

26 Automation products improve

29 Smart manufacturing is not a thing;

32 Process historians can be an integral

Process historians can help with distributed, cloud-based enterprises

34 Optimizing remote collaboration,

36 Modern control valves offer

38 Partial stroke valve testing

41 Hannover Messe Recap

57 Digital Edition Exclusive

Industrial Secure Router

Ethernet Switches Wireless AP/Bridge/Clients Cellular Gateways

Safeguard Your Facility

Now Get Moore Industries Alarm Trips

Demand Moore Reliability

To learn more about the SPA2IS and Moore Industries family of

Record set n-1

Record set n-2

P1 Neural networks in process control:

P8 Developing high-performance HMIs:

61 Safety diagnostics system;

10 Apps for Engineers

14 Control Engineering International

Brushless dc motor (left)

Advanced robotics help manufacturing.

3D holographs for advanced manufacturing

More resources posted daily at:

Process Manufacturing Discrete Manufacturing

Networking & Security

Education & Training

Webcasts for credit

 Next-generation Industrial HMIs

NEWSLETTER: IIoT REPORT

Use IIoT to improve

Point, click, watch

Oil & Gas Engineering

You cant afford not to know. See it all at thinkallied.com/sensors

THINK AGAIN IIoT

To take advantage of increased

communications needed for Industrial

als for an IIoT retrofit kit, said Jacob Goodwin,

Cooperation of information technology

Mark T. Hoske, Content Manager

Contributing Content Specialists

Next-generation Industrial HMIs