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tM
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rin
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Si
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MAY 2016
Decrease
ncrease 4% to 6%
Increase
9%
Vol. 63
Number 5
4%
2%
2
31%
54%
ncrease 1% to 3%
Increase
18
Features
18 Control Engineering
Salary and Career Survey
34
MAY 2016
CONTROL ENGINEERING
36
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MAY 2016
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P1
Departments
8 Think Again
Advice on integrating legacy technology with IIoT
P8
Products
64 Back to Basics
Control system power and grounding forensic exam
aids reliability.
62
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16
17
www.controleng.com
CONTROL ENGINEERING
MAY 2016
| 5
MAY
Trending
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New Products
Control Systems
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
Info Management
Webcasts
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.
MAY 2016
CONTROL ENGINEERING
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.
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Reliable Detection
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1.800.433.5700
Allied Electronics, Inc 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
input #5 at www.controleng.com/information
An Electrocomponents Company.
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.
MORE
MAY 2016
CONTROL ENGINEERING
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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?
14
MAY 2016
CONTROL ENGINEERING
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
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and productivity and to enable customers to implement pioneering solution concepts their way.
We think thats intelligent. www.sickusa.com
input #9 at www.controleng.com/information
16
MAY 2016
CONTROL ENGINEERING
Software construction
guidelines released
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
CONTROL ENGINEERING
MAY 2016
| 17
2016
COVER STORY
CAREER UPDATE
Control Engineering
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.)
Decrease
ncrease 4% to 6%
Increase
9%
Salary increases
ncrease
Increase
% to 3%
1%
31%
ncrease 1% to 3%
Increase
5% 4%
2%
2
54%
CONTROL ENGINEERING
Increase 4% to 6%
Stay the same
4%
Online, methods
Decrease
16%
18%
57%
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
74%
$13,290
80%
Personal performance
59%
Safety metrics
31%
Product profitability
29%
Quality metrics
26%
25%
21%
Uptime/downtime
18%
Energy efficiencies
Other
12%
4%
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
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 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
$103,444
$4,922
Masters degree
$104,338
$11,177
Doctoral degree
$109,000
$9,625
Average base
annual salary
Job title
Average base
annual salary
Average non-salary
compensation
Average base
annual salary
Average non-salary
compensation
$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 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
20
MAY 2016
CONTROL ENGINEERING
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
$136,500
$18,000
www.controleng.com
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our no
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input #11 at www.controleng.com/information
2016
COVER STORY
CAREER UPDATE
2016
2015
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%
Master's degree
College attendance
20%
4% 2% 7%
4%
6%
13%
44%
Dual bachelor's
degree
Bachelor's degree
22
MAY 2016
CONTROL ENGINEERING
Associate's
degree
2016
2015
2014
Mechanical (ME)
Chemical
Industrial
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%
20%
Engineering
Project management
Communication/
presentation
2016
2015
2014
Computer
Team-building
Marketing/sales
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
8%
3%
13%
39%
None
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.
MORE
ADVICE
GO ONLINE
At www.controleng.com/archives,
find more under this headline.
At www.controleng.com search
related topics.
24
MAY 2016
CONTROL ENGINEERING
Economy
Training, safety
Workload, throughput
Hiring, retention, wages, benefits
Technology transition, standards
Asset allocation, budget, energy costs
Politics
Mergers and acquisitions.
Education, training
Workplace strategies
Attitude
Communication
Engineering tips
Project management.
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
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
Software improvement
solutions use cases
CONTROL ENGINEERING
Life Just
Got Easier.
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.
www.honeywellprocess.com/experion
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
Processes.
Devices.
Locations.
28
MAY 2016
CONTROL ENGINEERING
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.
Product lifecycle
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).
Plan
Make
Deliver
Return
Figure 1: An example of
a supply chain using the
supply chain council (SCOR)
model. All figures courtesy:
BR&L Consulting
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
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
the headline at www.controleng.com.
CONSIDER THIS
What would it mean for the industry
if all facilities adopt smart manufacturing?
CONTROL ENGINEERING
MAY 2016
| 29
Plan
or
design
Acquire
or
develop
Install
or
deploy
Operate
and
maintain
Decommission
or
dispose
Concieve
Make
Design
Service
Dispose
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
Plan
Implement
Verify
and
operate
Detect
Assess
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
www.massa.com
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
CONTROL ENGINEERING
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
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,
cvavra@cfemedia.com.
systems?
MAY 2016
| 33
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
Go to www.controleng.com to learn
more about process historians and
remote monitoring.
CONSIDER THIS
What additional technologies can
plant managers and supervisors use
to optimize their facility?
34
MAY 2016
CONTROL ENGINEERING
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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
the headline at www.controleng.com.
CONSIDER THIS
Do the benefits of modern control
valves outweigh the challenges for
machine designers?
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
Figure: The valve/cylinder combination on the left is the traditional plumbing, and
the modern alternative is on the right.
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.
MAY 2016
| 37
tracopower.com
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
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),
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
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
www.controleng.com
MAY 2016
| 41
A dazzling opening
42
MAY 2016
CONTROL ENGINEERING
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
MAY 2016
| 43
44
MAY 2016
CONTROL ENGINEERING
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
MAY 2016
| 45
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
Winner
2015
We Deliver Results In Productivity
www.forcam.com
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
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 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
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
Figure 2: Manual or
automatic switching to an
alternate control strategy
may be required if entering an untrained control
space.
P2
MAY 2016
CONTROL ENGINEERING
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C
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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.
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
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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
Most control
platforms have
the necessary
instruction set
to configure a
neural network
model.
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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?
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
Improving usability
MAY 2016
| P9
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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
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.
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.
ONLINE EXTRAS
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.
CONTROL ENGINEERING
MAY 2016
| 57
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
At www.controleng.com/archives,
find more under this headline.
At www.controleng.com search
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.
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
CONTROL ENGINEERING
www.controleng.com
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
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
At www.controleng.com/archives,
find more under this headline.
At www.controleng.com search
related topics.
Going to market
CONSIDER THIS
What additional measures should
users take when it comes to the IIoT
and cybersecurity?
DE3
MAY 2016
CONTROL ENGINEERING
from bad actors like the people responsible for the Ukraine blackouts
or Dragonfly.
level of hackers.
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
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
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
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
Safety upgrade
Project management
$7,130
$5,060
$13,040
$18,400
Electrical design
$30,520
$20,240
Mechanical design
$4,800
Electrical hardware
$46,064
Mechanical hardware
$40,000
$0
$40,000
$9,000
$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.
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.
$8,533
$18,864
Electrical design
Mechanical design
$4,800
Electrical hardware
Mechanical hardware
$40,000
$29,440
Number
of change
orders performed
(out of 84
machines)
Average
cost per
change
order
with nonintegrated
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
Financial benefits
Operational benefits
DE7
MAY 2016
CONTROL ENGINEERING
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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
Go to www.controleng.com to learn
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
CONTROL ENGINEERING
1.
4.
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
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