October 2015 Full PDF Issue

October 2015 Full PDF Issue
October 2015
Modern
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Enhanc bilities increase
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IS YOUR SIS UP TO
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PROCESS AUTOMATION
UPGRADE SIMPLIFIES
CHEMICAL OPERATIONS
2015 AUTOMATION
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CONTENTS
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FEATURES
Process Automation Upgrade Simplifies 27 Supporting FSMA Compliance Chemical Plants’ Operations with Technology
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Is Your SIS Up to Current Standards? 33 Tips for Making the Most
People charged with process safety should review existing safety inof Asset Intelligence
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See how two chemical manufacturers optimized production, cut
downtime and more by upgrading their aging process control to a
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“The Windy City” embraces the industrial automation industry’s
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©The Journal From Rockwell Automation and Our PartnerNetworkTM, 2015, Volume 21 Number 5, is published six times a year by PUTMAN MEDIA, INC., 1501 E. Woodfield Rd., Suite 400N, Schaumburg, IL 60173.
(Phone 630/467-1300.) Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©The Journal From Rockwell Automation and Our PartnerNetwork 2015. All trademarks,
company names and product names referred to throughout this publication are used for identification purposes only and are the properties of their respective companies. All rights reserved. The contents of this publication
may not be reproduced in whole or part without consent of the copyright owner, including digital reproduction. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the industrial automation industry at no charge. To subscribe or unsubscribe, email Theresa Houck at [email protected] Putman Media Inc., which also publishes Chemical Processing, Control, Control Design, Pharmaceutical
Manufacturing, Plant Services, Food Processing and Wellness Foods, assumes no responsibility for validity of claims in items reported. Putman Media, Inc. is not affiliated with Rockwell Automation, Inc. “The Journal From
Rockwell Automation and Our PartnerNetwork” is a trademark of Rockwell Automation, Inc. and its use in the title and masthead of this publication is by license granted by Rockwell Automation, Inc. to Putman Media Inc.
Some photographs and other illustrations printed in this publication may be used with safety equipment removed or altered for illustrative purposes. However, in actual operation, it is recommended that all correct safety
procedures and equipment always be utilized.
4 THE JOURNAL | October 2015
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October 2015 | THE JOURNAL 5
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10/1/15 12:34 PM
VIEWPOINT
October 2015, Volume 22, No. 5
In Memory of Julie Cappelletti-Lange
Vice President 1984-2012
Putman Media, Inc.
1501 E. Woodfield Rd., Suite 400N
Schaumburg, Ill. 60173, 630-467-1300
Rockwell Automation
The Journal Executive Publisher
Rockwell Automation
Rebecca Archibald
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The Journal Managing Publisher
Rockwell Automation
Stanley A. Miller II
[email protected]
Putman Editorial & Sales Team
Publisher:
Mike Brenner
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Executive Editor:
Theresa Houck
[email protected]
Managing Editor:
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Advertising Sales Managers:
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Michael Connaughton
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AUTUMN AND AUTOMATION
FAIR — MY FAVORITE THINGS
>>
Autumn is my favorite time of year for many reasons
— of course, the cool, crisp air and the colorful foliage.
But fall also brings the annual Automation Fair® event. I love that
show and look forward to it every year. It’s the one place to find
the top companies in industrial automation, and a bunch of really
cool people. In this issue of The Journal, we provide a directory of exhibitors.
This year’s event is Nov. 18-19 at McCormick Place West in Chicago, with
more than 100 exhibitors that include Rockwell Automation and companies in its
PartnerNetwork™. The event provides a chance to learn about the latest integrated
control and information portfolio of products, services and solutions that can enable a Connected Enterprise.
Process companies shouldn’t miss the Process Solutions User Group (PSUG),
Nov. 16-17 just prior to the Automation Fair® event. In addition, this issue of The
Journal focuses on Process Solutions and provides valuable information about
process safety and advanced process automation.
While you’re at the show, enter The Journal’s drawing to win an Apple
iPhone. Just follow The Journal on Twitter, Facebook or Google+., then simply
visit our booth #1191, take a picture with me, and post it to your Twitter,
Facebook or Google+ account with the hashtag #autofair15TJ. As a bonus, you
could win a $10 iTunes gift card on the spot — in addition to being entered in
the iPhone drawing! Follow us on Twitter @thejournal_RA, on Facebook at
http://bit.ly/9NGXI or on Google+ at http://goo.gl/4oa9qZ.
You can sign up for the Automation Fair® event show daily e-newsletter at
www.automationfair.com.
So, stop by our booth #1191 to take a picture with me, post it to social media
to enter our drawing to win an iPhone, and possibly win a $10 iTunes gift card
on the spot. Until next time…
The Journal from Rockwell Automation and Our PartnerNetwork is published six times a year by Putman Media, Inc.
“The Journal from Rockwell Automation and Our PartnerNetwork” is a trademark of Rockwell Automation and its
use in the title and masthead of this publication is by license
granted by Rockwell Automation to Putman Media, Inc.
Other trademarks are property of their respective owners.
To subscribe or unsubscribe, e-mail Theresa Houck at
[email protected]
© The Journal from Rockwell Automation and Our PartnerNetwork 2015. All rights reserved.
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_07_Viewpoint.indd 7
Theresa Houck, Executive Editor
Download our free iPad app by searching
“ROKJournal” in your Newsstand Store!
October 2015 | THE JOURNAL 7
9/28/15 8:37 AM
Booth #1278
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9/28/15 9:29 AM
NEWS & NOTEWORTHY
NESTLÉ NAMES ROCKWELL AUTOMATION
SUPPLIER OF THE YEAR
Award recognizes collaborative efforts of key strategic suppliers
>>
Nestlé USA cited the
ability of Rockwell
Automation to develop innovative
solutions and provide extensive
support to commission new factory
lines when it awarded Rockwell Automation the 2014 North America
Procurement Supplier of the Year
award for technical procurement –
maintenance, repair and operations
(MRO). Nestlé USA also commended Rockwell Automation for
its superior ability to communicate
its supplier relationship management
scorecard throughout its organization, using it to gauge its performance as a supplier to Nestlé.
“This award recognizes many
years of innovative collaboration and
partnership between Nestlé USA and
Rockwell Automation,” said Andy
Murray, head of technical procurement, Nestlé. “Rockwell Automation
is one of our key strategic suppliers,
and I’m proud of all our collaborative efforts. Rockwell Automation
has innovative ideas, and we would
like to see even more. It’s a great
pleasure to present this award to
Rockwell Automation.”
“We’re honored to receive this
award,” said Keith Nosbusch, chairman and CEO, Rockwell Automation. “We pride ourselves on working
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_09_12_News.indd 9
Keith Nosbusch, chairman and CEO of Rockwell Automation (left), accepts the 2014 North America
Procurement Supplier of the Year award for technical procurement - maintenance, repair and operations (MRO) from Andy Murray, head of technical procurement, Nestlé.
with the best companies in the world,
and Nestlé is certainly one. Nestlé
was our first global account, and
our relationship is the benchmark
that we use to measure all others.
Whether it’s sharing technology
roadmaps or identifying mutual goals
and objectives, our close relationship
has driven this strategic alignment.
Thank you to Nestlé for being a great
customer and partner.”
The goal of the Nestlé Supplier Relationship Program is to
strengthen and develop relationships
between Nestlé USA and its key
suppliers, creating more value for
both organizations.
Rockwell Automation
www.rockwellautomation.com
October 2015 | THE JOURNAL 9
9/28/15 8:40 AM
NEWS & NOTEWORTHY
NEW EBOOK
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WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 8:40 AM
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PARTNERNET WORK SPACE
PROCESS SOLUTIONS: SUCCESS DERIVED
FROM CREATIVE COLLABORATION
>>
When it comes to complex solutions in strategic
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satisfy your needs, including your
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Our PartnerNetwork is comprised
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and key partners that are
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from both OEMs and system integrators. In the process industries,
you can count on the expertise of
our PartnerNetwork in a number of
areas as the seamless collaboration
with our partners allows Rockwell
Automation to deliver a more complete solution.
Many companies have legacy
process control systems that are installed in their facilities. These legacy
systems can be a challenge to support and a liability if a sudden failure
causes unscheduled downtime.
We’ve engaged in numerous projects that involved teaming between
Encompass™ Product Reference Partners and Solution Partners.
For example, by leveraging Softing (formerly OLDI) hardware and
RoviSys system integration services,
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_15_PartnerNetworkSpace.indd 15
we’ve created migration solutions
that expand a customer’s ability to
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the DCS. These tools have drastically
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October 2015 | THE JOURNAL 15
9/28/15 8:44 AM
16 THE JOURNAL | October 2015
TJ1510_16_24_CoverStory.indd 16
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 8:51 AM
Advance your process control by using a
modern DCS that provides plant-wide control,
easier skid integration, greater scalability, and
better connectivity with IT and business systems.
>>
Process-industry professionals are under constant pressure to help
increase their company’s market share, ensure compliance with evertightening regulations, and find new opportunities to improve productivity.
More often than not, they’re expected to do all this using the same automation
approach and control system strategy that they’ve relied on for decades. Yet only
so many improvements can be squeezed from old, antiquated technology.
Fortunately, numerous opportunities for operational improvements are available in the form of a modern distributed control system (DCS).
When first introduced, DCS solutions offered numerous benefits by connecting multiple controllers and points of access throughout a plant purpose-built to
handle process automation. However, now the traditional DCS is showing its age:
• A traditional DCS is built on proprietary technology disparate from
the other required automation systems in the plant. This has resulted in
fragmented control systems being used for the process area, packaging,
utilities, electrical and other systems. These multiple, separate automation
systems can be costly and difficult to integrate, while also restricting an
organization’s flexibility and responsiveness.
• The outdated platform lacks scalability. These systems were designed at a
time when plants were built from the ground up, making them uniquely
designed and nonscalable. As a result, integrating skid-based systems with
a traditional DCS typically is expensive. It requires additional hardware
and software, custom data-mapping, duplicate human-machine interface
(HMI) configuration and additional licensing.
• A traditional system is closed and only uses vendor-specific equipment. End users are usually limited to vendor-provided options for
servers, workstations and network switches, making integration with
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A modernized DCS can deliver the same core capabilities of a traditional system while addressing many of its challenges. Built on contemporary technology, a modern process platform enables plant-wide control,
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Leveraging scalable, multidisciplined control technology, a modern DCS is
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WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_16_24_CoverStory.indd 17
October 2015 | THE JOURNAL 17
9/28/15 8:51 AM
>> Rockwell Automation Encompass Partners
Support Process Automation
See Us at
Booth #1250
IT-OT
Convergence:
Shop floor to top floor data exchange
module for ControlLogix®
Transactional information: orders,
supply network, product design . . .
Many Encompass™ Product Partners
in the Rockwell Automation® PartnerNetwork™ (www.rockwellautomation.
com/partners) provide capabilities
that support batch management and
complement Rockwell Automation process automation
solutions. Visit their websites to learn more about how
they might help you.
AI-TEK Instruments, LLC: Process Instruments - Analytical
www.rockwellautomation.com/go/ai-tek
Ametek: Process Instruments - Analytical, Level
www.rockwellautomation.com/go/p-ametek
Badger Meter: Process - Control Valves, Intelligent Valve
Controllers, Flow Meter
www.rockwellautomation.com/go/p-badgermeter
Burkert Fluid Control Systems: Process - Control
Valves, Analytical, Flow Meter, Transmitter
www.rockwellautomation.com/go/p-burkert
Cape Software Inc.: Process Software - Simulation
www.rockwellautomation.com/go/p-cape-software
Control Station, Inc.: Process - Loop Tuning Software
www.rockwellautomation.com/go/p-controlstation
Endress+Hauser: Process - HART Interface Devices, Power
Supplies, Test Tools, Analytical, Configuration Tool, Flow
Meter, Level, Pressure, Recorder, Temperature, Transmitter
www.rockwellautomation.com/go/p-eh
eRPortal Software Group, LLC: Process Software Asset Management
www.rockwellautomation.com/go/p-erportal
Real-time data: alarms, events, states,
energy, diagnostics . . .
exida Consulting, LLC: Process - Alarm
Management Software
www.rockwellautomation.com/go/p-exida
Flowserve Corp.: Process - Intelligent Valve
Controllers, Process
www.rockwellautomation.com/go/p-flowserve
Fluke Corp.: Process - Test Tools
www.rockwellautomation.com/go/p-fluke
“Configure & Go” operation makes setup easy
with tManager® modules. Once configured,
the modules handle all data transfers,
buffering and logging.
Faster Implementation and Updates
Rock Solid Security
Easier Operation and Maintenance
Robust Data Handling and Auditing
softing.us/Journal2/ • 800.625.8678
©2015 Softing, Inc. All trademarks are property of
their respective companies.
18 THE JOURNAL | October 2015
TJ1510_16_24_CoverStory.indd 18
Helm Instrument Co. Inc.: Process Instruments - Load
www.rockwellautomation.com/go/p-helm
Metso Flow Control Inc.: Process - Control Valves,
Intelligent Valve Controllers, Process
www.rockwellautomation.com/go/p-metso
Mettler-Toledo, LLC.: Process Instruments - Transmitter
www.rockwellautomation.com/go/p-mettlertoledo
MTS Systems Corp., Sensors Division: Process
Instruments - Level
www.rockwellautomation.com/go/p-mts
MYNAH Technologies LLC: Process Software –
Simulation
www.rockwellautomation.com/go/p-mynah
Parker Pneumatic Division: Process - Control Valves
www.rockwellautomation.com/go/p-parker
continued on page 22
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 8:51 AM
Control. Manage. Optimize.
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The controller for a modern DCS
directly communicates with other
controllers in a plant without using
OPC bridges or other custom interfaces, even across system boundaries.
It also can be scaled to handle all automation systems, from small packaged
systems to large process applications.
This plant-wide control capability
can help improve productivity in ways
System integration just
got a whole lot easier
that are otherwise difficult to achieve
using a traditional DCS. For example,
the modern platform gives operators
easy access to real-time and historical
data that can help them more quickly
pinpoint issues or identify opportunities to improve productivity.
A contemporary process platform
also can help organizations reduce
energy consumption and costs.
Energy usage is one of the costs most
difficult to control in manufacturing
and other industrial environments.
For example, motors typically consume more than 60% of the energy
in an industrial facility. A modernized control system, however, can
easily integrate with motor control
devices, allowing plant personnel
to collect data from the devices and
then build an energy-management
strategy around the data.
A modern DCS with plant-wide
control also can help an organization
reduce its total cost of ownership
compared to a traditional system.
The savings come in multiple forms,
such as through reduced vendor
support for proprietary technologies,
reduced training for disparate systems, smaller spare-part inventories
and reduced licensing fees.
Scalable, Modular
Architectures
This fall, HMS Industrial Networks presents a new line of EtherNet/IP
Linking Devices. Based on Anybus technology, they enable ControlLogix®
and CompactLogix® controllers to seamlessly communicate with Modbus,
PROFIBUS, DF1 and serial devices.
The EtherNet/IP Linking Devices are fully integrated into Studio 5000™
through Custom Add-On Profiles, which simplify configuration and minimize
commissioning time.
For more information, visit us at www.hms-networks.com or call (312) 829-0601.
Visit HMS at Automation Fair - Booth 1232
®
20 THE JOURNAL | October 2015
TJ1510_16_24_CoverStory.indd 20
A traditional DCS uses a single-size
controller approach, which restricts
integration with other equipment,
while a modern DCS uses a scalable control platform to deliver the
right-size control at the right cost.
This eliminates the need to purchase
expensive control capacity that isn’t
needed. Engineering costs are dramatically reduced because the same
programming tools are used in a
contemporary platform, regardless of
the system’s size or I/O capacity.
With a traditional system, skid integrations require complex configuWWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
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UNDERSTANDING
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TJ1510_FullPageAds.indd 21
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www.amci.com
Visit
VisitAMCI
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AutomationFair!
Fair!® Booth
Booth#600
#600
10/1/15 8:36 AM
continued from page 18
Pepperl+Fuchs, Inc.: Process - HART Interface
Devices, Power Supplies
www.rockwellautomation.com/go/p-pepperlfuchs
ProSoft Technology: Process Instruments - Gas and
Oil Measurement
www.rockwellautomation.com/go/p-prosoft
Prozess Technologie: Process Instruments - Analytical
www.rockwellautomation.com/go/p-prozess
RACO Manufacturing & Engineering Co.: Voice
Alarm and Process Monitoring
www.rockwellautomation.com/go/p-raco
SAS: Process Software - Analytical
www.rockwellautomation.com/go/p-sas
Spectrum Controls Inc.: Process - HART
Interface Devices
www.rockwellautomation.com/go/p-spectrumcontrols
Ultra Electronics: Process Instruments - Temperature
www.rockwellautomation.com/go/p-ultra_electronics
VPG - BLH Nobel: Process Instruments Tension Measurement
www.rockwellautomation.com/go/vpg
rations that can increase risk and add significant costs. In
fact, studies have shown that the cost to integrate is often
50 to 70% of the actual skid-equipment cost.
On the other hand, a modern DCS provides scalable
system capabilities, such as HMI, batch management and
data collection that don’t require a server or workstation.
Now, an OEM can deliver a fully tested and functional
skid that will integrate into the DCS instantly, and the
end user is only responsible for binding the supervisory
control and data acquisition (SCADA).
Secure, Information-Enabled Designs
More manufacturers and industrial operators are converging their IT and operations technology (OT) systems into a
unified network architecture, which Rockwell Automation
refers to as The Connected Enterprise. This network convergence is giving organizations greater visibility into their
processes and enabling information-sharing in new ways.
Amid this greater level of connectivity, however, organizations can no longer tolerate an isolated DCS. Instead,
See Us at
Booth #1180
22 THE JOURNAL | October 2015
TJ1510_16_24_CoverStory.indd 22
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9/28/15 8:51 AM
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the DCS must support the seamless
industrial operators have had only one opflow of information, from machine to
tion for supporting a traditional control
Watch this video
machine and across the enterprise.
system: the original DCS provider. A
DCS
about
Modern
Based on a common IT infrastrucmodern platform offers multiple choices
ture, a modern control system supports
for implementation and support.
the use of commercial off-the-shelf servers,
Whether designing, commissioning,
workstations and servers, as well as the adopmaintaining or expanding the system,
tion of the latest information technology for automation.
the end user can either stick with the
A common IT infrastructure also helps IT professionDCS provider or turn to their preferred
als address industrial-control security as part of a larger
choice of in-house engineers, OEMs, system integrators, partcompany-wide security program, versus securing the plant
ners or other professionals. In certain cases, an end user might
and enterprise systems separately.
even want to use a combination of partners to meet a project’s
Additionally, a modern DCS is built on a foundation
specific requirements and schedule demands.
that uses open standards, such as Internet Protocol (IP)
A modern DCS is an ideal solution for process-industry
and EtherNet/IP™ to support a range of industrial applicaprofessionals seeking to retain the capabilities of a DCS while
tions and greater information-sharing.
creating new opportunities to increase productivity, cut integration costs and improve overall system flexibility.
Additional Benefits
A modern DCS also offers greater flexibility for delivering
and supporting
the system.
For decades,
manufacturers
and
F guide encompass
7-9-15.pdf
1
7/13/2015
2:25:28
Rockwell Automation PlantPAx® Modern DCS
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PROCESS AUTOMATION
UPGRADE SIMPLIFIES
CHEMICAL PLANTS’
OPERATIONS
See how two chemical manufacturers optimized
production, cut downtime and more by upgrading their aging process control to a modern
automated process control system.
>>
You might not know what you’ve got until it’s
gone, but you also might not realize how bad
you had it until something better arrives — especially if
you’ve been struggling with legacy process controls. In the
case studies below, two major chemical plants realized just
that after upgrading their legacy systems to better optimize
production and simplify operations.
Meeting Expansion Demands
Syngenta Crop Protection’s agricultural chemicals plant
in Omaha, Nebraska produces fungicides, herbicides and
insecticides, as well as protective coatings for seeds. The
plant is located on 42 acres with 26 buildings, six active
formulation facilities and five tank farms.
Over the years, the plant expanded operations and
upgraded from mechanical to automated process controls.
Syngenta migrated to Rockwell Automation beginning with
its packaging lines in 2008, its liquid continuous unit in 2010
and some of the tank farms from 2012-2014. Future conversions will include the plant’s continuous granular unit, more
tank farms and water treatment plant.
Syngenta’s systems engineer, Darrell Hanson, reports the
incremental improvements in programmable logic controllers
(PLCs) and human-machine interfaces (HMIs) made life better for the plant’s operators. However, their recipes remained
in the same hard-coded versions and hardware they’d used
since 1994, which made production inflexible and unable to
handle changes or new products without new construction.
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_27_31_F2-Chemical.indd 27
“Orders were written by the QA lab at the start of
each day, delivered to operations, accumulated through
the year, put in a box and archived,” says Hanson. “This
system was easy to understand as long as we ran the same
product and didn’t make a lot of changes.
“However, it was cumbersome and any significant changes,
such as adding an ingredient, changing a source, cooling in
a different step or agitating longer, had to be hard-coded into
ladder logic, which meant the process engineers had to ask
the PLC programmers for help and new facilities had to be
built,” he explains. “Additionally, historical data was limited,
and could only be used for trending graphs, and the legacy
hardware and HMI software was facing renewal.”
Hanson says the company was expanding their business
and applications, so they really needed a more dynamic
automation system and more flexible recipe management
that could maximize existing resources, minimize the need
to construct new facilities, and allow changes to be initiated
by process engineers to quickly meet customer demands.
“We also needed tighter controls to handle increased
quality and environmental standards, improved analysis
via historical data and reporting, and reduced field wiring
costs for new installations,” he says. “This is why we went
with Rockwell Automation for our system conversion.”
Flexible Recipe Management
Syngenta worked with Rockwell Automation system
integrator Interstates Control Systems Inc. (www.
rockwellautomation.com/go/p-interstates), and
implemented primary and secondary domain controllers
and servers from Rockwell Automation, including these
FactoryTalk® solutions (www.rockwellsoftware.com):
• FactoryTalk ProductionCentre® on an SQL server runOctober 2015 | THE JOURNAL 27
9/28/15 8:54 AM
ning Java for shop-floor interfaces.
• FactoryTalk Metrics for overall equpment effectiveness
(OEE) reporting.
• FactoryTalk AssetCentre for equipment management.
• FactoryTalk Batch.
• FactoryTalk View Site Edition.
• FactoryTalk Historian.
• FactoryTalk VantagePoint® reporting software running
on a VantagePoint SQL server.
All of these servers reside on ESXi virtualization servers
running VMware software (www.rockwellautomation.
com/go/vmware).
“Our new PLCs are programmed modularly, so recipes can
control groups of equipment following the ISA S88 standard,”
explains Hanson. “New recipes are set up by formulation engineers instead of PLC programmers. Orders are entered into
campaign manager software by QA lab personnel for each
batch to be produced, and operators start and control all batch
functions using FactoryTalk Batch.
“All data is recorded using FactoryTalk Historian, and
batch reports and KPIs are viewed with FactoryTalk VantagePoint,” he says.
FactoryTalk software and the PlantPAx® process automation system, along with other supporting solutions,
gave the company faster time-to-market and improved
asset utilization because they could use the same tanks to
make more and different products, and reduced total cost
of ownership and enterprise risk management.
Virtualizing Process Control
Going a step further in the St. Louis area, the controls engineering department at Jost Chemical Co. in Overland,
Missouri, worked with system integrator McEnery Automation (www.rockwellautomation.com/go/p-mcenery),
a recognized Rockwell Automation system integrator in
Fenton, Missouri, to combine and upgrade Jost’s distributed process controls, and migrate to the PlantPAx process
automation system built on virtual, redundant servers.
Jost manufactures 7 million kg/yr. of high-purity, inorganic salts for pharmaceutical, nutritional, food and specialty
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markets. Its more than 250 products
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capacity, custom and inconsistent PLC
and HMI code, and an overloaded process network with a flat architecture,”
says Rick Tissier, chemical engineering
leader at Jost.
Tissier says Jost wanted a plant-wide
control system that could be implemented in phases over a year or more,
and when complete, the system will:
• Make existing licenses compatible.
• Give its historian access to data
from all existing process areas
early in the project.
•Be flexible enough to allow integration of future process areas.
• Enable consistency in programming and operator graphics.
• Generate cost savings via efficient
implementation tools.
• Increase plant reliability.
Tissier adds that the Rockwell Automation Library of Process Objects
— such as device configurations from
templates, predefined alarms, variable-frequency drive (VFD) faceplates
and sequencer Add-On Instructions
(AOI) — was the determining factor
in Jost’s decision to standardize on
Rockwell Automation.
Steve McNamer, project manager at McEnery, says Jost had one
process, unsegmented control system
for all its applications and devices,
and much of its production traffic
was colliding and interfering internally. The process controls consist of
three Allen-Bradley ControlLogix®
programmable automation controllers (PACs) and two Allen-Bradley
CompactLogix™ PACs (www.
rockwellautomation.com/go/
tjcompactlogix), eight SLC™/MicroLogix™ PLCs, 29 Allen-Bradley
VFDs, 16 I/O chassis, three PanelView graphic terminals, six standalone FactoryTalk View Site Edition
station servers, and one server running FactoryTalk Directory Services
and FactoryTalk Historian.
Before virtualization, Jost had
2/26/15 10:41 AMWWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 3:31 PM
five physical servers. To virtualize its
computing, the company dispensed
with three of the original servers,
dedicated one to FactoryTalk Historian with access to data from all process areas, and used the last physical
server to establish eight virtual servers
running Hyper-V software for control
and supervisory tasks. FactoryTalk
VantagePoint provides process data to
managers on Jost’s business network.
“Using the library reduces implementation time for new and converted
processes and provides consistent operator interfaces,” says McNamer. “It also
enables Jost to convert existing process
areas one at a time by converting existing ControlLogix programming and
FactoryTalk View SE standalone applications to the PlantPAx format, and
then integrating them into distributed
FactoryTalk View and ViewPoint.”
automation of sequencing to reduce
batch times up to 10%, while milling improvements resulted in more
consistent product size and increased
on-stream time by 6%,” he adds.
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“My inspections will be safer and the larger
viewing area allows me to inspect more areas of
my electrical equipment.”
Notable Improvements
The library reduced Jost’s programming
costs by 25% for an estimated savings
of $10,000. Using Hyper-V reduced its
required Windows Server licenses for an
estimated savings of more than $10,000
for server hardware and software.
“Our Historian tag count has
increased to 750 tags,” says Tissier.
“Our engineers are using FactoryTalk
VantagePoint to suggest process
improvements and additional automation, and the PlantPAx system has
simplified the implementation of these
suggestions. In addition, our increased
automation has resulted in higher productivity by reducing batch time and
operator errors, but our operators are
requiring less training on graphics.”
Maximized precipitation rate
reduced product rework by 5% and
minimized time in centrifuge by
10% through improved cycle times.
Monitoring power consumption data
increased scheduled production without
exceeding peak power limits.
“Additionally, we increased
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[FOR LEAD-IN ART, USE AN
IMAGE OF A CHEMICAL MANUFACTURING PLANT ]
IS YOUR SIS UP TO CURRENT STANDARDS?
People charged with process safety should review existing safety instrumented system designs,
understand the standards, and know that certification doesn’t necessarily mean equipment standards
are met.
By Paul Gruhn, P.E., ISA Fellow, Global Process Safety Consultant, Rockwell Automation
Editor’s Note: This article is adapted from Gruhn’s full
white paper, “Is your existing Safety Instrumented System
up to current standards?” Visit http://goo.gl/2aHIXA to
download this free, comprehensive white paper to learn even
more about SISs, standards and how to determine if your
systems comply.
>>
Process safety is a major concern to anyone
who works in a process facility. An estimated
25,000 facilities covered by the Occupational Safety and
Health Administration (OSHA) Process Safety Management of Highly Hazardous Chemicals regulation will
most likely have safety instrumented systems (SISs), also
known as emergency shutdown systems.
Guidelines and standards for the design and implementation of safety systems have been in place in a variety
of industries since the 1990s. Many things change, even
standards. However, many other things don’t change — or
change very little — such as industrial processes that have
been running for decades.
So what are you expected to do with safety systems
installed prior to current standards? Are previous designs automatically assumed to be acceptable, or must
all older systems be ripped out and replaced? We explore
this topic.
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_33_38_F3-SIStandards.indd 33
How can I determine if my existing system is acceptable? There are two fundamental steps to determine if
your existing systems are acceptable:
• Step #1: Identify all safety instrumented functions
(SIFs) and determine what level of performance they
need to meet — that is, determine the required safety
integrity level (SIL) of each SIF.
• Step #2: Analyze/model/calculate the performance
of the actual hardware to see if it will meet the r
equired performance.
>> Free White Paper: Rethink What You
Should Expect From Your Distributed
Control System
Download the free white paper from Rockwell Automation, “Rethink What You Should Expect From Your Distributed Control System.” It describes the modern distributed
control system (DCS) — one that delivers all of the core
capabilities of a traditional DCS to address the requirements of process control, but is built on contemporary
technology that easily integrates with other automation
systems, operators’ activities and critical business systems. Visit http://goo.gl/EBS4Ft to download it now!
October 2015 | THE JOURNAL 33
9/28/15 8:56 AM
To help address step one, Figure
1 shows the performance requirements for the different SILs. Part 3
of the standard summarizes several
different techniques used around the
world for determining SIL, including the risk matrix, risk graph and
layer of protection analysis (LOPA).
It’s worth noting a statement made
in the introduction that says, “The
information provided is not of sufficient detail to implement any of
these approaches.”
According to the U.S. process
safety management regulation, process hazard analyses must be reviewed
every five years. Such review cycles are
an ideal time to formally identify all
safety functions and determine their
required performance targets.
To address step #2, many standards,
technical reports and books exist that
describe how to analyze hardware
performance to see if it will meet the
required performance. For example,
Clause 11.9 of the standard requires the
performance of a function to be verified
by a calculation. The standard also
includes fault-tolerant tables to show
what configurations of logic solvers and
field devices are suitable for different integrity levels. Figure 2 shows examples
>> Safety Integrity Levels
Safety
Integrity
Level
Probability of
Failure on Demand
(PFD)
Risk Reduction Factor
(1/PFD)
Safety Availability
(1-PFD)
4
≥ .00001 to < .0001
> 10,000 to ≤ 100,000
> 99.99 to ≤ 99.999
3
≥ .0001 to < .001
> 1,000 to ≤ 10,000
> 99.9 to ≤ 99.99
2
≥ .001 to < .01
> 100 to ≤ 1,000
> 99 to ≤ 99.9
1
≥ .01 to < .1
> 10 to ≤ 100
> 90 to ≤ 99
Figure 1. These are the performance requirements for the different safety integrity levels (SILs) when
trying to determine the required SIL of each safety instrumented function (SIF).
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34 THE JOURNAL | October 2015
TJ1510_33_38_F3-SIStandards.indd 34
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of technologies and configurations that
can meet different integrity levels.
For example, let’s imagine that your
team performs a SIL selection/determination study and determines that
a function needs to meet SIL 1. The
function and its field devices are separate from the control system. The safety
hardware consists of a pressure switch,
wired to a relay logic panel, which is
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then wired to a single solenoid operated
valve. All of the components are tested
on a yearly basis. Such hardware would
meet SIL 1 performance levels, and no
changes would be necessary.
However, let’s say the function
needed to meet SIL 2 and consists of
a single standard transmitter, wired to
a general purpose programmable logic
controller (PLC), which is then wired
to a single solenoid operated valve. Such
a configuration would not meet SIL
2 performance requirements, nor the
fault tolerance table requirements, and
a change would be necessary. There are
exceptions to every rule, but those are
beyond the scope of this article.
Does using certified devices
mean you will now comply? There is
a growing — and disturbing — trend
for users to specify that all field devices
be SIL rated and third-party certified,
usually to SIL 2 requirements. Vendors might also be using scare tactics
to get users to replace older noncertified devices with newer certified ones.
The standards are clear that
devices don’t require certification.
They have always permitted the use
of devices based on “proven-in-use”
criteria. However, many end users
find it difficult to thoroughly document this criteria.
Keep in mind, using certified devices isn’t the magic answer, and using such devices alone doesn’t mean a
company will be in compliance with
the standards.
When you see this logo,
download the free Layar
app from your app store,
scan this page with your
phone or tablet, then get
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36 THE JOURNAL | October 2015
TJ1510_33_38_F3-SIStandards.indd 36
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
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Safety Leaders Must Keep Up
Process safety remains a concern, with SIS
standards constantly changing. People charged
with maintaining the safety of the facility must
not only familiarize themselves with the latest
standards, but with so-called “grandfather clauses”
such as in ISA 84. Process safety involves a comprehensive understanding of these standards and
how they correlate to age-old industrial processes
that have not changed.
Your safety instrumented systems supplier can
help you determine if your current equipment
meets the standards in place and help you select
the solution that can meet your requirements
based on cost, safety integrity level, performance
and availability.
>> Sample Configurations & Technologies to
Meet Different SILs*
Sensors
Logic
Final Elements
SIL 1
• Switches
• Transmitters
• Relays
• Safety Solid State
• PLCs
• Safety PLCs
Standard valves
SIL 2
• Fault tolerant
sensors
• Transmitters with
comparison
• Safety transmitters
• Relays
• Safety Solid State
• Safety PLCs
• Fault tolerant valves
• Simplex valves with
partial stroking
SIL 3
Fault tolerant transmitters
• Relays
• Safety Solid State
• Redundant Safety
PLCs
Fault tolerant valves
with partial stroking
Figure 2. These are examples of technologies and configurations that can meet differ-
Rockwell Automation Process Solutions
ent integrity levels to help you analyze/model/calculate the performance of the actual
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hardware to see if it will meet the required performance.
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38 THE JOURNAL | October 2015
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n
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Controls 2 Power Mollers
Monitors roller motor life
Available Add-On-Profile (AOP)
Device Level Ring (DLR) built in
Discrete I/O (3 inputs and 5 outputs)
Onboard logic capability allows for custom ladder programming
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9/28/15 8:56 AM
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TJ1510_FullPageAds.indd 39
9/28/15 9:29 AM
AUTOMATION FAIR 2015
WELCOMES YOU TO CHICAGO
“The Windy City” embraces the industrial automation industry’s most exciting event on
November 18-19 as the world gathers to see and learn about the latest technology and techniques.
>>
Join us in Chicago, Illinois, where industrial
automation professionals from around the
world will gather for the 2015 Automation Fair® event
Nov. 18-19 at McCormick Place West. This is North
America’s best event to learn from technology, application and solution exhibits and educational sessions about
the latest control system network infrastructure using
IP-based networks like EtherNet/IP™, safety, power and
information technologies that support The Connected
Enterprise. The goal is to help you address risk, improve
production performance and make the most of your automation investments.
Through eight industry forums, 90 technical sessions
and 19 hands-on labs offered for free, Rockwell Automation experts, partners, customers and other industry pro-
40 THE JOURNAL | October 2015
TJ1510_40_47_F4-AutoFair.indd 40
fessionals will share insights on The Connected Enterprise
solutions that enable working data capital for better collaboration and more profitable decisions across enterprises
and supply chains.
Learn how Rockwell Automation and member companies in its PartnerNetwork™ (www.rockwellautomation.
com/partners) are integrating enabling technologies,
including the Internet of Things (IoT) and industrial
mobility, with automation control, power and information
software and solutions. You also can discover the latest
automation technology at the event’s exposition from
Rockwell Automation and more than 100 of its partners.
Download the full preshow program in PDF format at
http://goo.gl/STfNYJ, or visit www.automationfair.com
for more information.
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 8:59 AM
Process Solutions User Group (PSUG)
Annual Meeting
The week also features the popular Process Solutions User
Group (PSUG) Nov. 16-17 at McCormick Place West
just prior to the 2015 Automation Fair® event. This annual event attracts more than 800 attendees who gather
to learn about new technologies, process solutions and
their peers’ and leading industry experts’ best practices in
diverse process industries.
PSUG is a great place to learn from people who are improving their processes and creating new revenue streams.
This year’s event offers nine hands-on labs, more than 20
technical sessions, 25 customer application sessions, and
four “Ask the Expert” sessions showcasing real results using
the process solutions available from Rockwell Automation.
The participation fee is US$499 per person, and it covers event sessions, meals, refreshments and the Monday
night hospitality event at The Field Museum. Learn more
at http://psug.rockwellautomation.com.
Partners Demonstrate Products and Services
The 2015 Automation Fair® event is the best place to
examine top industrial technologies and services in one
place! You can talk to suppliers, see product demonstrations, and learn how these solutions can help you.
Exhibitors include Rockwell Automation and Encompass™
Product Partners, Solution Partners, OEM Partners and
Strategic Alliance Partners, all part of the Rockwell Automation PartnerNetwork™ program (www.rockwellautomation.
com/partners). See page 44 or visit www.automationfair.com
to see who will be exhibiting, and be sure to check out the
exhibitors to see how they can help you.
Industry Forums
The industry forums provide real-world examples of how
companies have increased their productivity and improved
efficiency. Representatives from various companies will
share their automation technology experiences and applications in the following industries:
• Automotive: Wed., Nov. 18, 9:00 a.m. - 11:30 a.m.
• Life Sciences: Wed., Nov. 18, 9:00 a.m. - 11:00 a.m.
• Chemical: Wed., Nov. 18, 1:00 p.m. - 3:30 p.m.
• Food & Beverage: Wed., Nov. 18, 1:00 p.m. - 3:30 p.m.
• Oil & Gas: Wed., Nov. 18, 9:00 a.m. - 11:30 a.m.
• Water Wastewater: Wed., Nov. 18, 1:00 p.m. - 3:30 p.m.
• Global Machine and Equipment Builders (OEMs):
Thurs., Nov. 19, 9:00 a.m. - 11:30 a.m.
• Power & Energy: Thurs., Nov. 19, 9:00 a.m. - 11:30 a.m.
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_40_47_F4-AutoFair.indd 41
Automation Fair® Event
NOVEMBER 18-19
MCCORMICK PLACE WEST • CHICAGO, ILLINOIS
8 a.m. - 5:30 p.m., Wednesday, Nov. 18
8 a.m. - 4 p.m., Thursday, Nov. 19
Register for FREE at www.automationfair.com or contact your local Rockwell Automation representative.
>> Join Us via Social Media!
You can stay connected with the Automation Fair®
event using your preferred social media channels:
Automation Fair: @automationfair
The Journal: @thejournal_RA
Rockwell Automation: www.facebook.com/ROK
Automation
The Journal: http://bit.ly/9NGXI
Rockwell Automation: http://goo.gl/0zBqUP
The Journal: http://goo.gl/W5dPW
Rockwell Automation: www.youtube.com/
ROKAutomation
The Journal: http://bit.ly/tjrayoutube
October 2015 | THE JOURNAL 41
9/28/15 8:59 AM
Hands-On Labs
The popular hands-on labs, offered up to four times a day,
allow you to work directly with Rockwell Automation
products. Once registered for the Automation Fair® event,
you can sign up for labs ahead of time online or sign up
on-site at the event.
When you’re not in a lab, you’re free to attend industry
forums and technical sessions and visit the Automation
Fair® exhibit show floor. Visit www.automationfair.com
for details.
Technical Sessions
Technical sessions are 60-minute presentations from leading industry and product experts. All sessions are available
on a first-come, first-served basis on site. No registration
is required. Visit www.automationfair.com for details,
schedule and topics.
User Experience Booth
For the third consecutive year, members of the Rockwell
Automation Usability and User Experience Community
will offer a space dedicated to gathering your feedback on
the tools you use to do your job. Rockwell Automation is
constantly working to improve your user experience with
its products, mobile applications and websites, and your
feedback is vital to those efforts.
Take this opportunity to have a stronger voice in shaping the future of the Rockwell Automation tools that
you need to do your job. Participate in interviews, online
surveys or usability tests with the Rockwel Automation
design teams.
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42 THE JOURNAL | October 2015
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WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 8:59 AM
At the last two Automation Fair® events, more
than 600 attendees participated in user research activities in the booth. All participants receive small
thank-you gifts, and six lucky winners will receive
door prizes such as tablets, Fitbit devices and Roku®
streaming devices. Stop by booth #389 to share
your feedback.
Attendance is Free
The Automation Fair® event is free, including lunch
and refreshments.
Download the free ROKEvents app from your
smartphone’s app store to plan for the event and use
during your time in Chicago.
Visit www.automationfair.com to register, or
contact your local Rockwell Automation representative.
Don’t forget to stop by The Journal’s booth #1191
while you’re there. Take your picture with Executive
Editor Theresa Houck to be entered in a drawing for
a free iPhone®!
Also, visit www.automationfair.com to sign
up for the free e-newsletter that will be published every day of the show with updates and
highlights of educational events and exhibitor
displays.
>> Win a Free Apple iPhone from The Journal!
Visit The Journal’s booth #1191 and take a
picture with Executive Editor Theresa Houck
to enter our drawing to win an Apple
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picture on one of those social media channels with the hashtag #autofair15TJ.
Once you post your picture, you’ll be included in the drawing to win an Apple iPhone, awarded after the event. Take
advantage of this fun contest. See you at the show!
Twitter: @thejournal_RA
Facebook: http://bit.ly/9NGXI
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WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_40_47_F4-AutoFair.indd 43
October 2015 | THE JOURNAL 43
9/28/15 8:59 AM
>> Exhibitors List*
COMPANIES
BOOTH NO.
COMPANIES
BOOTH NO.
COMPANIES
BOOTH NO.
ACP ThinManager................................................. 649
Belden................................................................ 485
Control Station, Inc............................................ 1091
www.rockwellautomation.com/go/acp
www.rockwellautomation.com/go/p-belden
www.rockwellautomation.com/go/p-controlstation
Advanced Energy................................................. 601
Block USA, Inc..................................................... 512
Cybertrol Engineering..........................................1178
www.rockwellautomation.com/go/advanced-energy
www.rockwellautomation.com/go/p-block
Advanced Micro Controls Inc. (AMCI).....................600
Bonitron.............................................................. 627
www.rockwellautomation.com/go/p-amci
www.rockwellautomation.com/go/p-bonitron
Aetna Group...................................................... 1090
Brady Corp........................................................ 1184
www.rockwellautomation.com/go/cybertrol
Data-Linc Group................................................... 671
www.rockwellautomation.com/go/p-datalinc
Datalogic Automation........................................... 212
www.rockwellautomation.com/go/p-aetna
www.rockwellautomation.com/go/p-brady
www.rockwellautomation.com/go/p-datalogic
Ametek............................................................... 519
Burkert Fluid Control Systems............................... 650
DENSO Robotics...................................................990
www.rockwellautomation.com/go/p-ametek
Apex Dynamics Inc............................................. 1278
www.rockwellautomation.com/go/p-apex
Applied Control Engineering, Inc......................... 1085
www.rockwellautomation.com/go/p-act
ARPAC................................................................. 690
www.rockwellautomation.com/go/p-arpac
www.rockwellautomation.com/go/p-burkert
Bussman by Eaton (Formerly Cooper Bussman)...... 501
www.rockwellautomation.com/go/bussman
Cisco Systems..................................................... 1045
www.rockwellautomation.com/go/cisco
Codian Robotics................................................... 591
www.rockwellautomation.com/go/p-codian
Commerce Controls Inc......................................... 691
AT&T................................................................... 647
Autodesk............................................................. 554
www.rockwellautomation.com/go/p-cci
www.rockwellautomation.com/go/p-autodesk
www.rockwellautomation.com/go/p-conceptsys
Badger Meter....................................................... 791
www.rockwellautomation.com/go/p-badgermeter
Barry-Wehmiller Design Group, Inc....................... 220
www.rockwellautomation.com/go/bwdesign
Concept Systems Inc............................................. 226
Control Magazine................................................1193
www.controlglobal.com
Control Design Magazine.....................................1193
www.controldesign.com
www.rockwellautomation.com/go/p-denso
DE-STA-CO – Camco Products................................ 113
www.rockwellautomation.com/go/p-destaco
Elwood Corporation - High Performance Motors....1171
www.rockwellautomation.com/go/p-elwood
EN Engineering.................................................... 515
www.rockwellautomation.com/go/p-enengineering
Endress+Hauser................................................... 878
www.rockwellautomation.com/go/p-eh
Energy Control Technologies............................... 1087
www.rockwellautomation.com/go/p-ectech
EPLAN Software & Service.................................... 526
www.rockwellautomation.com/go/p-eplan
eRPortal Software Group, LLC............................... 449
www.rockwellautomation.com/go/p-erportal
ESTeem Wireless Modems....................................1118
www.rockwellautomation.com/go/p-est
eWON................................................................ 1183
www.rockwellautomation.com/go/ewon
Exlar Corp...........................................................503
www.rockwellautomation.com/go/exlar
FANUC............................................................... 1351
www.rockwellautomation.com/go/p-fanuc
FLIR Systems......................................................1218
www.rockwellautomation.com/go/p-flir
Fluke Corp........................................................... 579
www.rockwellautomation.com/go/p-fluke
Food Processing Magazine...................................1193
www.foodprocessing.com
General Cable.................................................... 1235
www.rockwellautomation.com/go/p-generalcable
Grace Engineered Products, Inc......................312, 313
www.rockwellautomation.com/go/p-grace
Hammond Power Solutions, Inc............................. 818
www.rockwellautomation.com/go/p-hammond
Hardy Process Solutions.......................................884
www.rockwellautomation.com/go/p-hardy
Harmonic Drive, LLC........................................... 1270
www.rockwellautomation.com/go/harmonic-drive
Helm Instrument Co. Inc......................................1110
www.rockwellautomation.com/go/p-helm
Hermary Opto Electronics, Inc............................... 685
www.rockwellautomation.com/go/p-hermary
HMS Industrial Networks AB............................... 1232
www.rockwellautomation.com/go/p-hms
Hubbell Electrical Systems.................................... 507
www.rockwellautomation.com/go/p-hubbell
Imperx, Inc........................................................1015
www.rockwellautomation.com/go/imperx
INCO Engineering S.R.O........................................ 790
www.rockwellautomation.com/go/inco
44 THE JOURNAL | October 2015
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WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 8:59 AM
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TJ1510_FullPageAds.indd 45
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>> Exhibitors List*
>> Rockwell Automation Exhibits*
COMPANIES
BOOTH NO.
Interstates Control Systems Inc........................................................................ 1114
www.rockwellautomation.com/go/p-interstates
Energy Management...........................................1100
Essential Components........................................... 806
FIRST Robotics................................................... 1478
Global Lounge..................................................... 328
Industrial IP Advantage....................................... 1340
Information Software.......................................... 1035
Integrated Architecture....................................... 1256
Intelligent Motor Control....................................... 832
Process Solutions............................................... 1078
Product Selection Toolbox..................................... 927
Safety Solutions...................................................400
Solutions & Services............................................. 856
The Connected Enterprise Pavilion......................... 945
User Experience.................................................. 289
item North America.......................................................................................... 401
www.rockwellautomation.com/go/p-itemna
Itoh Denki USA, Inc......................................................................................... 1016
www.rockwellautomation.com/go/p-itohdenki
Kepware Technologies..................................................................................... 1128
www.rockwellautomation.com/go/p-kepware
KTR Corp........................................................................................................1180
www.rockwellautomation.com/go/p-ktr
Laird............................................................................................................... 206
www.rockwellautomation.com/go/laird
Leviton Mfg Co................................................................................................. 200
www.rockwellautomation.com/go/p-leviton
LinMot USA, Inc................................................................................................670
www.rockwellautomation.com/go/linmot
LinTech...........................................................................................................1285
www.rockwellautomation.com/go/lintech
Littelfuse Inc.................................................................................................. 1011
www.rockwellautomation.com/go/p-littelfuse
LOCCIONI Group (AEA S.R.L.)............................................................................ 593
>> Visit The Journal at Booth #1191!
www.rockwellautomation.com/go/loccioni
Marathon Motors..............................................................................................518
www.rockwellautomation.com/go/p-marathon
Matrix Technologies Inc.....................................................................................216
www.rockwellautomation.com/go/p-matrix
Maverick Technologies.....................................................................................1225
www.rockwellautomation.com/go/p-maverick
MECCO............................................................................................................ 570
www.rockwellautomation.com/go/mecco
Melfi Technologies Inc...................................................................................... 890
POSITAL
POSITALMotion
Motionand
andPosition
PositionSensors:
Sensors:
Ready
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forthe
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www.rockwellautomation.com/go/p-melfi
Mersen.............................................................................................................413
www.rockwellautomation.com/go/p-mersen
Mesta Electronics Inc........................................................................................ 445
www.rockwellautomation.com/go/p-mesta
Metso Flow Control Inc..................................................................................... 420
www.rockwellautomation.com/go/p-metso
Mettler-Toledo, LLC......................................................................................... 1179
www.rockwellautomation.com/go/p-mettlertoledo
Molex.............................................................................................................1070
www.rockwellautomation.com/go/p-molex
Stainless
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Analog..
■■
■■
Motorola Solutions........................................................................................... 585
www.rockwellautomation.com/go/motorola
MTE Corp......................................................................................................... 560
www.rockwellautomation.com/go/p-mte
MTS Systems Corp, Sensor Division.................................................................... 584
www.rockwellautomation.com/go/p-mts
MYNAH Technologies LLC.................................................................................. 770
www.rockwellautomation.com/go/p-mynah
Nidec-Shimpo Corporation................................................................................ 544
See
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www.rockwellautomation.com/go/p-nidec
NJM Packaging...............................................................................................1372
www.rockwellautomation.com/go/p-njm
Nook Industries, Inc......................................................................................... 726
www.rockwellautomation.com/go/nookindustries
www.posital.com
www.posital.com
Numatics, Inc................................................................................................. 1008
www.rockwellautomation.com/go/p-numatics
Outbound Technologies Inc............................................................................... 232
www.rockwellautomation.com/go/p-outboundtech
46 THE JOURNAL | October 2015
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WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 8:59 AM
>> Exhibitors List*
COMPANIES
BOOTH NO.
COMPANIES
BOOTH NO.
Owl Computing Technologies, Inc.......................... 451
SeQent................................................................684
www.rockwellautomation.com/go/owlcomputing
www.rockwellautomation.com/go/p-seqent
Panasonic Corporation of North America ............... 447
SMC Corporation of America................................. 870
www.rockwellautomation.com/go/p-panasonic
Panduit ............................................................ 1051
www.rockwellautomation.com/go/p-panduit
Paper Converting Machine Company ..................... 513
www.rockwellautomation.com/go/p-pcm
Parker Pneumatic Division.................................. 1279
www.rockwellautomation.com/go/p-smc
Softing ............................................................. 1250
www.rockwellautomation.com/go/softing
SolidWorks Corp................................................... 590
www.rockwellautomation.com/go/solidworks
Southwire Co....................................................... 891
www.rockwellautomation.com/go/p-parker
www.rockwellautomation.com/go/southwire
Pentair Equipment Protection (Hoffman®)......... 1361
Spectrum Controls, Inc........................................ 1000
www.rockwellautomation.com/go/p-pentair
Pepperl+Fuchs Inc................................................ 784
www.rockwellautomation.com/go/p-pepperlfuchs
Pharmaceutical Manufacturing Magazine...............1193
www.pharmamanufacturing.com
Phoenix Digital Corp.......................................... 1071
www.rockwellautomation.com/go/p-phoenixdigital
Plant Services Magazine......................................1193
www.plantservices.com
Point Eight Power Inc........................................... 318
www.rockwellautomation.com/go/pointeightpower
POSITAL FRABA Inc..............................................500
www.rockwellautomation.com/go/p-fraba
Post Glover Resistors.......................................... 1272
www.rockwellautomation.com/go/p-postglover
Powerit Solutions.................................................502
www.rockwellautomation.com/go/powerit
Powerohm Resistors, Inc. ................................... 1334
www.rockwellautomation.com/go/p-powerohm
Prime Controls LP ...............................................1170
www.rockwellautomation.com/go/p-prime
ProSoft Technology..............................................534
www.rockwellautomation.com/go/p-prosoft
Prozess Technologie............................................. 693
www.rockwellautomation.com/go/p-spectrumcontrols
Stahlin Non-Metallic Enclosures............................. 718
www.rockwellautomation.com/go/stahlin
STOBER Drives Inc................................................ 826
www.rockwellautomation.com/go/p-stoberdrives
Stone Technologies............................................. 1029
www.rockwellautomation.com/go/p-stone
Stratus Technologies........................................... 1079
www.rockwellautomation.com/go/p-stratus
Systems Interface Inc......................................... 1470
www.rockwellautomation.com/go/p-sii
SyTech, Inc. ...................................................... 1464
www.rockwellautomation.com/go/p-sytech
TCI, LLC ..............................................................644
www.rockwellautomation.com/go/p-tci
Tempered Networks............................................. 291
www.rockwellautomation.com/go/p-tempered
Teledyne DALSA .................................................. 123
www.rockwellautomation.com/go/p-teledyne-dalsa
The Journal Magazine.........................................1191
www.rockwellautomation.com/thejournal
Thermo Systems, LLC...........................................1116
www.rockwellautomation.com/go/p-thermosystems
www.rockwellautomation.com/go/p-prozess
Tissue Machinery Company SpA.......................... 1286
Putman Media....................................................1193
www.rockwellautomation.com/go/p-tmc
www.putmanmedia.com
Tolomatic, Inc...................................................... 700
Pyramid Solutions, Inc......................................... 469
www.rockwellautomation.com/go/tolomatic
www.rockwellautomation.com/go/p-pyramid
Ultra Electronics................................................... 568
RACO Manufacturing & Engineering Co.................. 213
www.rockwellautomation.com/go/p-ultra_electronics
www.rockwellautomation.com/go/p-raco
United Converting Srl..........................................1190
Revere Control Systems Inc................................... 471
www.rockwellautomation.com/go/p-ucsrl
www.rockwellautomation.com/go/p-revere
Wachter Electric Co. Inc........................................ 491
RF IDeas, Inc......................................................1019
www.rockwellautomation.com/go/wachter
www.rockwellautomation.com/go/p-rfideas
Weiss North America Inc....................................... 412
Rice Lake Weighing Systems............................... 1226
www.rockwellautomation.com/go/p-ricelake
River Consulting................................................. 1290
www.rockwellautomation.com/go/p-riverconsulting
Ross Controls....................................................... 321
www.rockwellautomation.com/go/p-rosscontrols
RoviSys Co......................................................... 1081
www.rockwellautomation.com/go/rovisys
Roxtec Inc........................................................... 626
www.rockwellautomation.com/go/p-roxtec
SAS..................................................................... 390
www.rockwellautomation.com/go/p-sas
Schweitzer Engineering Laboratories Inc................ 618
www.rockwellautomation.com/go/p-schweitzer
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_40_47_F4-AutoFair.indd 47
Stop traveling on
site for support!
Let’s stay Cosy!
www.rockwellautomation.com/go/p-weiss
WIN-911 Software ..............................................1173
www.rockwellautomation.com/go/win-911
WITTENSTEIN, Inc.................................................800
Secure VPN
Remote Access
for machine builders
• Firewall friendly solution
• 3 Million VPN Connections
• Free VPN service
www.rockwellautomation.com/go/p-wittenstein
Wulftec International Inc.................................... 1273
www.rockwellautomation.com/go/p-wulftec
Zebra Technologies Corporation...........................1212
www.rockwellautomation.com/go/zebra-technologies
Zeppelin Systems USA, Inc.................................... 479
www.rockwellautomation.com/go/p-zeppelinsystems
(*As of Aug. 25, 2015. Refer to on-site
directory for most current list of exhibitors.)
Booth #1183
www.ewon.us
Pittsburgh, PA|412 586 5901
October 2015 | THE JOURNAL 47
9/28/15 8:59 AM
SUPPORTING
FSMA COMPLIANCE
WITH TECHNOLOGY
The FDA sets the food safety compliance objectives, and leaves it up to you to figure out how to get
there. Here is some guidance on what you’ll need.
By Jim Toman, Lead Consultant - Food and Beverage Services and Ian Tooke, Director - Consulting Services, Grantek
Systems Integration
>>
The Food Safety Modernization Act (FSMA,
www.fda.gov/Food/GuidanceRegulation/
FSMA) will revolutionize food safety in the United States,
and will have a ripple effect across the globe. Of the seven
rules proposed by the U.S. Food & Drug Administration
(FDA) thus far, the majority are hundreds of pages in
length, and understanding what’s required can be confusing. With additional rules still expected to come, it can be
difficult to plan for the future.
So far, the FDA has released the proposed rules shown
in the illustration on page 50, with court-defined dates
for finalization. While regulatory compliance is a baseline
requirement, the ability to concurrently satisfy other business needs helps ease the burden of implementing a change.
Food Safety Evolution
The Hazard Analysis Critical Control Point (HACCP)
approach to food safety has been gaining ground over the
past several decades, and is required for certain types of food
products in the United States (seafood, juice, meat and poultry). FMSA will require the breadth of the food industry to
build upon HACCP and formalize a comprehensive system
to address food safety. Standards will be instituted for fresh
produce, food processing, transportation and imports.
Rather than issuing product-specific requirements, the
FDA sets the objective and leaves it up to companies to
figure out how to get there. While the FDA doesn’t require
the use of any specific system, technology, or the use of
any degree of automation, it’s clear that the FDA wants
companies to embrace technology.
Regardless of the approach taken, several overarching “ingredients” are needed for FSMA compliance
48 THE JOURNAL | October 2015
TJ1510_48_51_F5-FSMA.indd 48
that also are critical for your brand protection:
• Rapid Response. Whether it’s recognizing that a
process is out of control or providing records to the FDA,
companies need to be able to respond quickly.
• Consistency. When considerable effort goes into
developing a plan to achieve food safety, the consistent
implementation of those policies is critical.
• Documentation. The foundational role that documentation will play in demonstrating that food safety is
under control — even when a regulator or auditor isn’t
looking — can’t be overstated.
• Analysis. The food industry collects a lot of data.
However, bringing the data together to make sense of
the bigger picture often is lacking. Trending data allows
companies to anticipate looming issues and also can reveal
opportunities to optimize systems and efficiency. While
FSMA revolutionizes the FDA’s food safety authorities, an
individual company’s path to compliance should be more
of an evolution, not a revolution.
Preventive Controls
Preventive controls prevent, eliminate or reduce the
known hazard to an acceptable level for safe consumption
of food. Under FSMA, the FDA will have a legislative
mandate to require comprehensive, science-based preventive controls across the food supply.
Moving forward, some activities that have historically
been considered current Good Manufacturing Practices
(cGMPs) may be updated and modernized, thus falling
under Preventive Controls.
Within the realm of Preventive Controls, process
controls are the most familiar. These are the controls
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 9:01 AM
that are typically associated with
HACCP and are recognized as the
critical control points for food safety.
With Preventive Controls, the FDA
expects that food manufacturers will
continue to heavily rely upon process
controls. Consistent with what is
seen in existing HACCP regulations,
the FDA would require that the following approach be followed:
Validation. Whatever process
control is selected must work. If
a process is being employed, for
example, to control for Salmonella,
the food producer must be able to
show that the process will destroy
the pathogen effectively. In this
example, this means knowing the
expected and worst case levels of
the pathogen so that the amount of
“kill” can be determined.
Then, the parameters that will
accomplish this reduction need to be
tested. This should be done using the
food products to which the process
will be applied, under the most realto-life conditions possible, including
using the actual equipment that will
be used during production.
Establishing Parameters. Validation studies will help a company
establish the conditions needed for
an effective process. Any change,
such as a change in formulation
or processing equipment, should
prompt a re-evaluation of the parameters. Automated recipe management
for equipment and process parameters can help food producers meet
this need.
Monitoring. Once the parameters
are set, they must be monitored. A
Historian database can be used to
capture these process parameters such
as temperature, pressure, time, etc.
Corrective Actions. System
failures need to be anticipated, and
facilities need to show they have
thought through what could go
wrong and have a plan to address
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_48_51_F5-FSMA.indd 49
issues if they occur. When issues
do occur, the facility needs to keep
records of the event and show they
followed the course of action specified in their food safety plan.
Verification. The FDA has proposed a few ways facilities will need
to show that their entire food safety
system is working as anticipated.
Recordkeeping and documentation,
Automating functions.
Simplifying operations.
Modernizing protection.
Bebco EPS® 5500 Series
Advanced,
high-end, Zone 2 / Div. 2 purge system
Automatic
systems for alarm, purging, and power to the enclosure
Programming
and temperature control with leakage compensation
www.pepperl-fuchs.com/purge
Booth #784
October 2015 | THE JOURNAL 49
9/28/15 9:01 AM
and a review of those records as well as a re-evaluation of
the overall food safety plan, would be required.
Examples of Preventive Controls
Allergen Control. For facilities that have identified
food allergens as hazards that are reasonably likely
to occur, implementing allergen controls would be
required. This can encompass several different activities, including appropriate sanitation between different
allergens as well as runs without allergens, appropriate
storage of allergens, material verification, and label
control and verification.
>> FDA Proposed FSMA Rules and Defined Dates for Finalization
FDA’s FSMA Regulation
Final Rule Deadline
Preventive Controls-Human Food
Aug 30, 2015
Preventive Controls-Animal Food
Aug 30, 2015
Produce Safety
October 31, 2015
3rd-Party Accreditation of Auditors
October 31, 2015
Sanitary Transport
March 31, 2016
Intentional Adulteration/Food Defense
May 30, 2016
Large businesses have 12 months to comply once the FSMA rules are finalized; small businesses have 24 months to comply; and very small businesses
have 36 months, according to the FDA.
FAULT TOLERANT...SELF HEALING
FIBER OPTIC COMMUNICATION MODULES
(RING, BUS, STAR...ANY & ALL CABLE ARCHITECTURES)
Over 60 Miles
(96 km) Apart
1756 PLUG-IN
MODULES
(ControLogix)
UL and UL/C Class I,
Div 2, CE Mark
Ethernet, EtherNet/IP, ControlNet®,
1771 PLUG-IN
MODULES
(PLC 5)
Data Highway Plus, Remote I/O,
DH-485, DF1, Modbus, Modbus Plus,
and RS-232/485 Communication Networks
1746 PLUG-IN
MODULES
(SLC)
IN CHASSIS / STAND ALONE
DIN Rail,
STANDALONE
MODULES
PANELMOUNT
STANDALONE
MODULES
Booth #1071
Plug-&-Play, Multi-Drop EtherNet/IP Module for ALL Redundant Ring Networks
Easiest, Fastest, Friendliest Diagnostics EVER!
50 THE JOURNAL | October 2015
TJ1510_48_51_F5-FSMA.indd 50
7650 East Evans Rd.
Bldg A
Scottsdale, AZ 85260
Phone: +1 (480) 483-7393
Fax: +1 (480) 483-7391
Email: [email protected]
www.phoenixdigitalcorp.com
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 9:01 AM
Supplier Verification. In some cases, a facility might
not have a way to control a hazard, instead relying on a
supplier for control. In this instance, the FDA is expected to propose that supplier controls be enacted in
such a way that the receiving facility is assured that their
supplier is adequately controlling hazards.
Certificates of Analysis (CoAs) by suppliers have little
value if a receiving company doesn’t know how to review
and verify them properly. The preferred approach is to automate the review of COAs. Implementing an automated
traceability and genealogy system covering raw materials
receipt and linking laboratory analysis of raw materials
samples to the specific received lots can create a traceable
and searchable record that proves control.
Forensic Traceability. An automated track-and-trace
system, with genealogy records including key data elements (KDEs) captured at critical tracking events (CTEs)
and further detail of equipment and production routings,
can facilitate fast forensic investigation and build trust
with the FDA and consumers.
Magnetostrictive
noncontact technology;
resolution to 1 micron
Supports Star, Line or DLR topology
Three standard M12
connectors — 1 power,
2 communications
Compliance Isn’t Optional
FSMA is coming, and change is just around the corner.
Leading companies are continually on the lookout for ways to
enhance their operations while maintaining profitability.
Grantek Systems Integration Inc., based in Burlington,
Ontario, Canada, is a Rockwell Automation Enterprise
Solution Partner, an elite group of professional IT service
organizations that have demonstrated design, delivery and
sup¬port competency around the enterprise class of Rockwell
Automation® FactoryTalk® manufacturing information solutions. The firm is a system integrator and solution provider
specializing in manufacturing IT solutions, manufacturing
automation solutions, industrial safety solutions and manufacturing consulting services.
Grantek Systems Integration Inc.
www.rockwellautomation.com/go/p-grantek
Rockwell Automation Solution Partner Program
www.rockwellautomation.com/go/sitj
Wide input power
supply range (7–30V)
may reduce external
power supply
requirements
Set IP address from
network PC or the last
octet via the RapidRecall
DIP switches
Booth #519
What to do
when analog won’t do.
RapidRecall™
module stores
all user
configuration
settings
Introducing the ReadyLink™ Network LDT
Five status LEDs
monitor LDT and
network status
Status bits
warn of position/
velocity outside of
programmed range
Built-in web
pages for easy
configuration
Automation solutions require accurate feedback of continuous
position regardless of the application environment. Analog position
sensing devices can have shortcomings in automation applications,
including limited features, resolution and cable lengths. That’s why
the ReadyLink Linear Displacement Transducer is a far better solution.
Feature for feature, it lets you do—and measure—so much more.
Learn more about this smart device technology at ametekfactoryautomation.com.
© 2014 by AMETEK. All rights reserved.
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_48_51_F5-FSMA.indd 51
October 2015 | THE JOURNAL 51
9/28/15 9:01 AM
TIPS FOR MAKING
THE MOST OF
ASSET INTELLIGENCE
Integrating maintenance and operations in real time
can create a universally integrated IT infrastructure
designed to drive superior asset performance.
By Dr. Ananth Seshan, 5G Automatika Ltd.
Editor’s Note: This article is adapted from the white paper, “Automated Best Practices for Driving Asset Performance” from 5G Automatika Ltd. Visit http://goo.gl/Z0WIWp to download the free, full white
paper that has additional information about commercially available
off-the-shelf asset intelligence systems, and case studies demonstrating
asset intelligence best practices.
>>
With the advent of smart manufacturing and Industrial Internet of Things (IoT), interconnectivity
between devices and disparate systems, and synergistic collaboration between multiple business processes and stakeholders within a manufacturing enterprise, are becoming a reality.
Be it mining, oil and gas, water or power utilities, or process
or discrete manufacturing manufacturing, major players are
using real-time intelligence to make informed decisions using
a universally integrated IT infrastructure.
52 THE JOURNAL | October 2015
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WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 9:05 AM
Strain gage input
for POINT I/O
™
In this article, we look at real-time integration between
maintenance and operations and how maintenance can
drive superior asset performance.
Asset Performance
Asset performance management (APM) is the term used
for maximizing asset availability and reliability. When
these two metrics are improved, the return on assets (production assets) is maximized. Because a major investment
of the manufacturing (or utility) industry typically is on
production assets, achieving a better return on assets increases shareholder value, and therefore is a strategic goal
for most large enterprises.
Given technology advancements, it’s possible to capture
machine (production asset) data automatically, transform
the raw machine data to metadata, discover actionable
intelligence from the metadata, and generate proactive
maintenance actions to maintain continuous and superior
asset performance.
Therefore, “opportunistic” maintenance interventions
can be generated in response to the “emerging” real-time
intelligence on the condition of a plant-floor asset. This
capability is useful beyond just maintaining operational
performance. In many instances, asset degradation can relate to regulatory noncompliance, a safety risk or a quality
Two
channels per module.
analog-to-digital
conversion.
24-bit
of 1 count
per 100,000 counts.
Resolution
Built-in
averaging.
with all
industry load cells and
weigh scales.
Compatible
Booth #1110
Helm Instrument Company, Inc.
361 West Dussel Drive
Maumee, OH 43537
P: 419.893.4356 F: 419.893.1371
E: [email protected] www.helminstrument.com
The ability to generate
actionable intelligence and
automated workflows can result
in numerous benefits.
failure leading to a major financial loss. Therefore, APM is
seen as a multidisciplinary and continuous improvement
program as opposed to being a one-time initiative.
Asset Intelligence
As stated earlier, to perform good and continuously effective APM, there is a need for generating proactive realtime actions based on intelligence and not data. According to some reports, about 15,000 terabytes of data can
be generated every day. This is a lot of data. Most of the
collected data, unless converted into metadata and further
into intelligence, is not useful.
Asset intelligence systems are software programs that
enable the collection of raw data from plant assets, controllers and drives and convert them into actionable intelligence. The conversion process will involve selecting data
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Top mount (F3) conduit box
BlueMAX® 2000 Brakemotor
Intergrated Stearns Brake
ranging from 6 to 105 Lb/Ft.
2000:1 constant torque
Booth #518
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October 2015 | THE JOURNAL 53
MarathonAd_TheJournal_3.25x4.875_Aug-Issue2015.indd 1
TJ1510_52_54_F6-Automated.indd 53
A Regal Brand
100 East Randolph St., P.O. Box 8003
Wausau, WI 54402-8003
PH: 715-675-3311
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ew
N
to be converted, aggregating data in multiple dimensions
and automatically deriving some useful conclusions about
the “status” or “condition” of assets.
The output of an asset intelligence system is the automatic generation of useful and timely maintenance actions
in resident asset management systems (or computerized
maintenance management system, CMMS) to proactively
respond to a certain emerging behavior of assets that could
result in a failure.
DOE 2016 compliant
transformers are here
Benefits of Real Time Asset Intelligence
- Low Voltage Distribution & Medium Voltage Transformers
HPS is proud to announce the availability of a complete line
of DOE 2016 compliant Low Voltage and Medium Voltage
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Booth
#818
www.hammondpowersolutions.com
MORE THAN
AN ENCLOSURE
The ability to generate actionable intelligence and automated workflows can result in the following benefits:
• Reduction in unplanned downtimes.
• Reduction in failure rates (or improvement in reliability.
• Removal of non-value-added labor due to the integration of workflows and business processes between plant
and enterprise.
• Unified visibility of production and maintenance information – in fact, maintenance actions are driven by the
need for enhanced performance.
• Reduction in the maintenance spend year on year.
• Mitigation of regulatory risks.
• Increased return on assets.
5G Automatika Ltd. is a participating Encompass™
Product Partner in the Rockwell Automation® PartnerNetwork™. Based in Ottawa, Ontario, Canada, the company
supplies the Enterprise Gateway (EG) off-the-shelf solution
that integrates production and maintenance operations of an
enterprise in real time for enhanced production performance.
5G Automatika Ltd.
www.rockwellautomation.com/go/5g-automatika
Rockwell Automation Encompass
Product Partner Program
www.rockwellautomation.com/go/tjencompass
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>> Download the Free White Paper!
Register to download 5G Automatika Ltd.’s free, complete white paper, “Automated Best Practices for Driving Asset Performance,” at http://goo.gl/Z0WIWp.
Get additional info about commercially available offthe-shelf asset intelligence systems, and case studies
demonstrating asset intelligence best practices.
®
54 THE JOURNAL | October 2015
TJ1510_52_54_F6-Automated.indd 54
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 3:34 PM
ENCOMPASS SHOWCASE
AMCI in Rockwell Automation Sample Code Library
Linking Device Eliminates Bottlenecks
AMCI shares nearly 50 free downloadable
The SST™-PB3-REM linking device from Molex
sample programs in the Rockwell Automation
eliminates bottlenecks, increases efficiency, and
Sample Code Library for configuring and
provides an elite PROFIBUS solution for Logix-
programming Rockwell Automation devices and
based Rockwell Automation control systems. First,
compatible products. AMCI’s sample programs
we created an AOI for Logix platforms, making
cover many of their Rockwell Automation-compatible products, including
integration more proficient. Next, we ensured no
their PLC Plug in modules, stepper drives and EtherNet/IP™ devices.
ladder logic programming was required to configure
Written using RSLogix™ 500 and Studio 5000 , the programs can be
the module. Then, we used paging through four CIP-
easily incorporated into new or existing ladder logic programs, making
based connections to optimize throughput back to
adding AMCI products to your system a quick and efficient process.
the controller. This unique feature allows for up to 2-kB input plus 2-kB
Over 12,000 downloads to date, get yours! http://goo.gl/icdDqm
output of PROFIBUS process data. http://goo.gl/xKaXPS
A DVA N C E D M I C R O C O N T R O L S I N C . (A M C I)
MOLEX
Programmable Actuators from Nook Industries
Need PROFIBUS in Your CompactLogix?
Nook Industries offers a
Need to connect your CompactLogix™ to
complete line of industry-
a PROFIBUS network? ProSoft Technology
leading programmable
can make the connection for you with our
actuators specifically
in-chassis interface — at the price of a
designed for continuous
gateway. The PROFIBUS DPV1 Master module
duty and long service life.
for CompactLogix integrates with RSLogix™
They incorporate a direct or toothed belt drive for high mechanical
5000 using a sample Add-On Instruction,
efficiency while also allowing for quieter running performance. Nook
which helps cut your configuration time. The
PA actuators can be supplied with either ball or acme screw and either
module also supports ComD™, enabling asset-management software
servo or stepper drive systems, inline or parallel. Nook PA actuators
to remotely configure, commission, maintain and diagnose your fieldbus
provide unmatched load (1,500 lbs. max.) and speed (25 in./sec.)
devices, helping you cut your maintenance costs. A slave interface for
capabilities. Visit http://rockwell.nookinfo.com.
CompactLogix also is available. http://psft.com/BAZ
N O O K I N D U S T R I E S, I N C .
P R O S O F T T E C H N O L O GY
RACO’s AlarmAgent.com Now Features SaaS for
OPC Connectivity
Troubleshoot Flow Performance | Dynasonics
Ultrasonic Portable Flow Meter
New SaaS application
Designed for systems engineers to quickly trouble-
AlarmAgent.info sends real-time
shoot problems and verify performance during
remote operations data from
system commissioning and diagnostics, the Dyna-
AlarmAgent.com to the user’s
sonics® DXN portable clamp-on ultrasonic meter
HMI/SCADA software for
by Badger Meter is the perfect tool for any job
immediate issue resolution and
site. Easy to install by clamping onto the outside
predictive analysis. Users can
of the pipe, the DXN measures flow using noninvasive ultrasonic sensors. Its
customize the visual data representation for easy comprehension, while
portability makes it an excellent choice for measuring flows throughout the
the built-in .NET Framework ensures data security. Demo AlarmAgent.
process system infrastructure to verify sensor, pump and valve performance.
info at the Automation Fair ® event, booth #213! www.racoman.com
800-433-5263 | www.badgermeter.com/DXN
R AC O M A N U FAC T U R I N G A N D E N G I N E E R I N G C O.
BADGER METER
®
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_55_57_ECS.indd 55
October 2015 | THE JOURNAL 55
9/28/15 9:09 AM
ENCOMPASS SHOWCASE
FLOWave Flow Meter
1326AB AC Servo Motors Now Available
Our patented FLOWave technology eliminates
Elwood High Performance Motors now supports 1326AB servo motors.
sensor elements in the measuring tube, making
While no longer available from Rockwell
many flow measurement medium contact problems
Automation, 1326AB-Series motors from Elwood
a thing of the past. SAW (surface acoustic waves)
provide lifetime support for productive equip-
technology makes this possible. FLOWave indicates
ment. Elwood motors allow the use of existing
its device status every time with a light being related
RSLogix™/Studio 5000®, motor data files,
to Namur NE107 definitions and does not require maintenance activi-
cables, mounting flanges/adaptors and cou-
ties. This allows for shortened downtimes resulting in remarkable life-cycle
plings for drop-in replacements. Elwood’s 1326AB motors are form, fit, and
cost reductions for users. SAW is the only flowmeter technology that can
function equivalents for original equipment. The Series builds on Elwood’s
distinguish between laminar and turbulent flows. www.rockwellautomation.
legacy servo motor family, including indefinite support for F, H, N, S, W
com/go/p-burkert
and 1326AS Series motors and cable sets. www.elwood.com/motors
B U R K E R T F L U I D C O N T R O L S YS T E M S
E LWO O D C O R P.
IR Viewing Windows
Expanded Anybus Wireless Bridge Offering
Infrared (IR) cameras are
Expanded suite of Anybus
essential tools for predictive
Wireless Bridge products from
maintenance, but they
HMS now offer more solu-
can only inspect what
tions for connections through
they can see. With their
hazardous areas, hard-to-reach
unparalleled field of view,
locations or moving installations
IR windows from SafeSide®
where cables are not desirable.
give you a quick, efficient
Several versions are available
way to safely inspect electrical equipment. SafeSide® Polymers do not
for both serial and industrial
degrade when exposed to acids, alkalis, UV, moisture, humidity, vibra-
Ethernet communication.
tion, and high frequency noise — a guarantee no crystal IR window
www.anybus.com/products/wireless_bridge.shtml
can provide. http://hubs.ly/y0Fdwp0
G R AC E E N G I N E E R E D P R O D U C T S, I N C .
H M S I N D U S T R I A L N E T WO R K S
EtherNet/IP Process Video Recorder
eNetMeter DN
IMPERX’s EtherNet/IP™ Process Video
The most advanced diagnostic on the mar-
Recorder (EIPVR) is an event-recording sys-
ket today now takes a proactive approach
tem that captures high-speed video when
to DeviceNet diagnostics. Molex’s eNetMe-
you need it. This product is EtherNet/IP
ter DN not only continuously watches your
conformance tested, compatible with IEEE
network, it now sends email notifications
1588 and uses Power over Ethernet ca-
based on established parameters. Pas-
bling for a simple installation. EIPVR records up to 60 seconds of video
sive 24/7 monitoring through a PLC or PC
at 250 fps, automatically saves video to a server and plays video for
uses a local EtherNet/IP™ connection for
quick feedback. EIPVR is triggered via EtherNet/IP and is ODVA tested
delivery of real time diagnostics. eNetMeter
and approved as well as compatible with EtherNet/IP Devices. http://
DN: the tool that goes further to keep your
imperx.com/rockwell-encompass-partner-program
network up and optimized. http://goo.gl/s9ndXZ
IMPER X
MOLEX
56 THE JOURNAL | October 2015
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WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 9:09 AM
ENCOMPASS SHOWCASE
Complete Sealing Solution
High Availability Solutions
The Roxtec EzEntry™ is a complete
Stratus Technologies focuses
range of light-weight cable entry
exclusively on helping manufac-
seals for cabinets and enclosures. The
turers keep critical plant opera-
seals are designed for easy single-
tions up and running without
sided installation and enable routing
interruption. Stratus delivers a
of pre-terminated cables. They are
range of solutions that includes
UL certified with versions available
software-based continuous
for standard knock-outs. The seals
availability, fault-tolerant
are delivered as kit solutions with an
servers; availability consulting and assessment; and remote systems
integrated compression unit and adaptable modules.
management services. Learn more at www.stratus.com/RA.
www.rockwellautomation.com/go/p-roxtec
R OX T E C I N C .
S T R AT U S T E C H N O L O G I E S
Excel Reports and Forms for Industry
EPLAN Electric P8 Electrical Design Automation
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traditional CAD tools. Electric P8 automates
studio,” complete with our easy-to-follow
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FastStart wizard. Your reports are ready
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ing and error-checking. Users can create,
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over 40 manufacturers, including Rockwell
information, contact us at (508) 520-9957 or [email protected] Down-
Automation. It also translates projects into 17
load your free evaluation copy from www.SyTech.com.
languages. Request a 30-day trial at eplanusa.com.
SY TECH INC.
E P L A N S O F T WA R E & S E RV I C E L L C
Mechatronics Solved: Linear Actuators
& Positioning Systems
Full-Color InView Industrial Message Displays
Spectrum Controls’ new full-color
Two industry leaders have come together to pro-
InView industrial message displays
vide one-source solutions: Nook Industries, with
are designed to handle the harsh
the broadest selection of ball screws, jacks and
conditions of the factory floor
actuators; and AMCI, a leading provider of
while maintaining industry leading
PLC-based motion control systems. Now Allen-
brightness and longevity. Available in two sizes and in NEMA 4 and
Bradley Nook/AMCI PLC customers can easily
4X enclosures, the displays communicate productivity, status and alarm
source their mechatronic solutions from trusted
conditions to the factory floor. Along with the full color display, Spectrum
experts. Visit http://partner.nookinfo.com to find the solution that’s right
Controls offers a new communications module firmware upgrade
for you — get access to the Nook/AMCI solution guide, or contact us
focused on improving the existing software and implementing new
for a totally custom solution.
display features. www.rockwellautomation.com/go/p-spectrumcontrols
N O O K I N D U S T R I E S/A M C I
S P E C T R U M C O N T R O L S, I N C .
®
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL TJ1510_55_57_ECS.indd 57
October 2015 | THE JOURNAL 57
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Endresss+Hauser, Inc. EPLAN Software & Service
ESTeem Wireless Modems
eWON Inc.
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KTR Corp.
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Molex Incorporated
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Nook Industries
Pepperl+Fuchs
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SyTech Inc.
WITTENSTEIN, Inc.
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18
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54
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2
See Us at
Booth #626
PROTECT YOUR EQUIPMENT. INCREASE EFFICIENCY.
Standardize with Roxtec Cable and Pipe Seals to:
•
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Seal pre-terminated cables without cutting off the connectors
58 THE JOURNAL | October 2015
TJ1510_58_ProductFocus-AdIndex.indd 58
PHONE 918 254 9872
EMAIL [email protected]
WEB www.roxtec.com/us
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
9/28/15 3:36 PM
What keeps you awake at night?
Machine performance
Reducing downtime
Safety
Aging equipment
Training
Manufacturing and industrial automation are expected to change
more dramatically in the next five years than in the past two decades.
The Connected Enterprise has quickly advanced from a revolutionary
concept to an unprecedented catalyst for optimizing industrial production.
See the newest and most advanced power, control and information solutions
in the industry and how it will bring you forward.
Looking for even more? Attend the Process Solution Users Group. For more details, visit www.psug.rockwellautomation.com
November 18-19, 2015
McCormick Place, Chicago, IL
Register today for the Automation Fair® event!
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