by Gary Mintchell | May 31, 2016 | Automation, News, Process Control, Safety, Security
Schneider Electric automation President Gary Freburger talked about living in a time of immense change in the industry. Sandy Vasser of ExxonMobil (my last report) discussed some of the disruptions his team is working on. One of the disruptions relates to configurable I/O.
At the conference, Schneider Electric announced an update to its Intelligent Marshalling solution. It now contains redundancy capabilities. Likewise the Tricon CX compact safety system has been enhanced with the addition of the 3902X TMR universal I/O module.
The Foxboro Evo FBM 248 and Tricon CX 3902X remove the dependency among control and safety system design and the installation of I/O systems. Universal I/O offerings for Foxboro Evo and Triconex enable process automation professionals to seamlessly adapt to last-minute I/O design changes and provide backup to eliminate the impact of any process downtime.
“Upgrading our award-winning Intelligent Marshalling solution to include redundancy and safety capabilities demonstrates our commitment to providing the connected solutions our customers need to improve the safety, reliability and efficiency of their plants and business operations,” said Chris Lyden, senior vice president of strategy, Process Automation, Schneider Electric. “Configuring control and safety systems I/O can be costly, labor-intensive and subject to change. With their additional flexibility, the Foxboro FBM 248 and Tricon CX 3902X I/O offerings allow our customers to adjust to unforeseen module changes and errors with little impact to installation time. That can drive huge savings when it comes to project execution and operations.”
With its universal I/O and software-configurable modules, Intelligent Marshalling allows users to configure I/O points from anywhere in the plant or in the world. It also enables flexible options for future expansions and upgrades, as well as significant cost savings by reducing marshalling infrastructure, increasing I/O density per cabinet, reducing field and maintenance labor costs and drastically reducing the need for onsite replacement inventory.
Modicon Finds a Home
Modicon, and factory automation in general, has been a bit like an orphan step child for years at Schneider. The group now reports into the automation group under Freburger. It’s a learning experience for the process automation people—new language, new distribution, new service options. But things seem to coalescing well.
The PlantStruxure PES hybrid control system, build on a Modicon PLC platform, received its moment in the sun at the conference. Schneider Electric has added redundant controllers to the PlantStruxure PES system. Today, 50 percent of PlantStruxure PES projects require at least one pair of redundant controllers within the configuration. PES V4.2 meets the next generation of requirements with the M580 ePAC and the ability to lock down ports within a single configuration environment. With the highest levels of cybersecurity available on the market, PES V4.2 ensures nearly 100 percent uptime for customer systems.
“As IT and OT converge, we need solutions that boost plant connectivity and security,” said Lyden. “PlantStruxure PES enhances the ability of plant operators, engineers and managers to take better advantage of process and energy management data, which better enables them to improve maintenance, increase asset reliability and uncover additional operational efficiencies, all in a more secure environment. By making our PlantStruxure PES automation system secure and future proof by design, we are meeting the needs of tomorrow’s production facilities, today.”
A core feature of the Modicon M580 ePAC is its Ethernet-based architecture. Integration into the PES solution improves system management and provides customers with a level of standard communication, guaranteeing a future-proof system. Additionally, new services will be available for engineering and commissioning, which will make navigating a control program easier, as well as improve performance when making project changes. PlantStruxure PES V4.2 is also equipped with ready-to-use application and industry libraries, allowing systems to be built more quickly and with lower engineering costs. And by integrating energy-management features from other Schneider Electric automation and power devices, such as Altivar drives, the system will help users realize higher energy cost savings.
by Gary Mintchell | Mar 1, 2016 | Automation, Internet of Things, Networking, Operations Management, Safety, Wireless
Enabling Industrial Internet of Things (IIoT), Reliability, Scalability, and pursuing Real ROI encompass the current mantra of Fluke. Maybe you only know that company for its multimeters or infrared cameras. Well, there is much more behind the curtain.
The company has focused product development on mobile solutions, wireless communications, and data. This quarter’s product releases reflect all of that.
Infrared
The new Fluke Ti450 Infrared Camera takes focus to a new level of clarity with MultiSharp Focus. An out-of-focus thermal image can give you data that may lead to misdiagnosis — potentially costing you thousands — with no way to correct it once it has been captured, short of taking new images. This new infrared camera solves this problem by delivering images automatically focused throughout the field of view.
“We are excited to announce this new technology, because it makes a real difference in situations where you have objects at multiple distances that you want in focus. Places like substations, motors driving a long production line, or electrical panels with components at varying depths,” notes Chris Rayburn, thermography business director.
MultiSharp Focus is a new technology that rapidly takes multiple images and combines them to produce one in-focus image. The advanced focusing system enables users to capture an automated, focused image of multiple targets at once, delivering the image clarity needed by professional thermographers and maintenance managers to produce top-quality results and avoid costly rework.
Waveforms
Today’s industrial machinery is more reliable and efficient, but can also be more difficult to troubleshoot because of the complexities of its advanced systems. The new Fluke ScopeMeter 120B Series Industrial Handheld Oscilloscope features Connect-and-View technology that recognizes signal patterns and automatically sets up the scope’s triggering, amplitude, and time base eliminating the typical trial-and-error setup process. Once the waveform is captured, the new IntellaSet intelligent measurement detection automatically selects key measurements based on the acquired waveform type and displays the most relevant measurement values (for example, Vrms and Hz for a line voltage signal, or Vpeak-peak and Hz for a square wave), helping technicians easily identify and characterize potential signal faults.
The 120B Series also features Event Capture function that captures and identifies elusive intermittent events and lists all those events that exceed a predetermined threshold. This lets technicians identify key events quickly, rather than combing through large data sets, reading by reading.
Fluke Connect
The Industrial Internet of Things is all about connections and data. As part of Fluke Connect— a system of wireless test tools that communicate via the Fluke Connect app, or Fluke Connect Assets software, a cloud-based solution that gathers measurements to provide a comprehensive view of critical equipment status — the 120B Series can automatically record waveform data to the Fluke Connect app on smartphones or tablets ensuring accuracy and eliminating manual recording of data. Those measurements are then wirelessly uploaded to the cloud and can be combined with measurement data from multiple Fluke Connect test tools to create and share reports from the job site via email and collaborate in real time with other colleagues, increasing productivity in the field. Storing then comparing and contrasting waveforms of specific asset test points over time enables maintenance engineers to better identify and troubleshoot conditions that can lead to failures.
Work Orders
Fluke introduces Work Orders, the latest enhancement to the Fluke Connect Assets, an asset management software solution that works with the Fluke Connect system of wireless test tools. Using this new Fluke Connect Assets feature maintenance managers can:
- View complete work order history coupled with measurement data related to a specific plant asset
- Create work orders from anywhere
- Confidently assign the job to the appropriate technician and balance the task with other work orders in the system.
Technicians are provided with actual measurement data right in the work order allowing them to better understand the problem and work instructions.
The Fluke Connect system allows entire maintenance teams to capture and wirelessly share data via their smartphones. Using the AutoRecord feature measurements are transferred directly from Fluke Connect wireless test tools – eliminating transcription errors – and can be uploaded to FlukeCloud storage. Measurements can be assigned to a specific asset for sharing and analysis. Technicians can collaborate with their colleagues to discuss problems while sharing data and images in real time with ShareLive video calls, which speeds problem solving, decision-making and approvals.
Clamp Meters
Often the most frustrating task for electricians and maintenance technicians is to troubleshoot intermittent faults because they rarely occur at convenient times. The new Fluke Connect-enabled 370 FC Series Clamp Meters log measurements to pinpoint intermittent faults precisely without the need for the technician to be present. Those measurements are then wirelessly transmitted to the Fluke Connect app on smartphones or tablets and automatically uploaded to the cloud, keeping technicians outside the arc flash zone and away from dangerous moving machinery, improving safety.
The CAT IV 600 V, CAT III 1000 V safety-rated clamp meters offer advanced troubleshooting performance to capture a wide range of measurements with a single tool, including:
- Proprietary in-rush measurement technology to filter out noise and capture motor starting current exactly as the circuit protection sees it;
- Integrated variable frequency drive low pass filter (376 FC and 375 FC models only) for accurate motor drive measurements;
- True-rms voltage and current for accurate measurements on non-linear signals;
- 500 mV dc measurement range to interface with other accessories (376 FC and 375 FC models only);
- Expanded measurement range to 2500 A ac with the iFlex flexible current probes, which provide access to large conductors in tight spaces.
As part of Fluke Connect— the industry’s largest system of software and more than 30 wireless test tools — technicians can wirelessly transmit measurement data from the 370 FC Series clamp meters and other test tools to their smartphones for secure storage on the Fluke Cloud and team access from the field. With the Fluke Connect smartphone app, technicians can combine measurement data from multiple Fluke Connect test tools to create and share reports from the job site via email and collaborate in real time with other colleagues with ShareLive video calls, increasing productivity in the field.
by Gary Mintchell | Nov 4, 2015 | Events, Safety
I’m wrapping up my coverage of the EHS Today Safety Leadership Conference held last week in Greenville, SC. I covered the Technology Track sponsored by Rockwell Automation.
Steve Ludwig, safety program manager at Rockwell Automation, presented on the impact of the evolving workforce on safety.
Workforce changes
“We are facing a shortage of skilled workforce, and it is a global issue,” began Ludwig. “The average age of skilled worker is 56, and this demographic is prone not to delay retirement. Add to this the fact that birth rates have declined for the last 35 years, so we do not have the usual situation of increasing population to fuel economic growth.
There are now more inexperienced workers who are more at risk. This is not just a situation for your plant, but also for the plants of all your suppliers. Businesses face supply chain interruption, reputational / brand risk. Businesses face not only an aging workforce that may be prone to injury, but also a younger, less experience workforce that tend to have more frequent acute injuries.
When Ludwig asked attendees, “How do we improve with a changing workforce?” most responded that they were proactively going out to schools to recruit and evangelize manufacturing. They were also assuming much responsibility for helping train young people.
Connected enterprise for safety
Jeff Winter of system integrator Grantek discussed connecting the enterprise for safety. He noted a problem that continues to exist is that dashboards rely on manual data collection and input.
There are three “Eras” of safety technology–initially just preventing access; then detecting access (something that increased both safety and productivity); today controlling access (integrated safety into machine, about as productive as you can get).
“EHS must get a chair at the table when data collection and analysis are being discussed in the plant or company,” he concluded. Winter continued with this advice, “Ask for data on actions such as emergency stops, intrusions, shut downs.”
Beyond lockout, tagout
Turning to electrical safety specifically, Jimi Michalscheck business development manager for safety looked at going beyond Lockout Tagout (LOTO). His point was how to balance safety with production. He posited a system of engineered safety control, which he called a new way of addressing LOTO.
“If you haven’t designed an alternative, then you must use LOTO (OSHA). To prevent unexpected restart of the equipment during service from causing harm to employees.”
Engineering safe alternatives. Think of your machine as simple components. For example, a case packer. Notorious for frequent need for getting into it, so also for citations. Using Alternative Protective Measure (APM), design the machine in components. Task specific, area specific, documented (know that the service area is protected for the reach of the worker). APM developed must provide the same or greater level of protection as LOTO in order to comply with CFR1910.147.
by Gary Mintchell | Nov 3, 2015 | Automation, Safety
Mike Douglas, Sr. Manager of Health and Safety Engineering, at General Motors, spoke at the Technology track of the EHS Today’s Safety Leadership Conference on steps to getting to a safety consciousness within a company. He had led the team that changed GM from the top down into a safety-conscious company. The process included promoting safety as a brand within the company.
Using the model of the Safety Maturity Index, Douglas discussed culture, capital, and compliance.
Cultural involves what people say at the water cooler. You have to ask is safety a priority or a value. Priorities change but values don’t. That means working to assure safety is in the company DNA.
If you have achieved bringing safety into a key place in the company’s DNA, then it becomes time to put your money where your values are. In the Safety Maturity Index, this is called Capital. Douglas asks, “Have you committed to investing in design for safety? You must commit resources to perform the required due diligence to meet safety requirements. Further, ask, “Has your company performed throughput improvement analysis around safety investments?”
Finally, you must work on Compliance, the last stage of the Safety Maturity Index. Douglas asks, “Does your company follow a management system? Do you have specific performance standards that support the management system? Have resources been allocated and responsibilities assigned (governance, requirements, accountability)?
I noticed Douglas’ talk fit into a few trends most speakers discussed. One of these is the observation that business benefits accrue when safety becomes an integral part of not only culture, but also design. Douglas mentioned throughput (less downtime, for example) as a benefit that even financial managers can recognize.
Douglas had a final observation for Safety Leaders, “You have to be able to defend the system.” Change agents and leaders must either have this ability or develop it in order to achieve success.
by Gary Mintchell | Oct 30, 2015 | Automation, Safety
Rockwell Automation sponsored a technology track at the EHS Today Safety Leadership Conference October 27-28, 2015 in Greenville, SC. The seven sessions discussed a variety of issues facing Safety Leaders in industry. These sessions focused on machine safety. Process safety is an entirely different ball game.
Shawn Galloway, president of ProAct Safety, and Steve Ludwig, safety program manager, presented ideas on Improving Safety Performance in a quick, TED-Talk-like pair of presentations. Even though this was the “Safety Technology” track, the seemingly soft topic of company culture was the topic to set the table for the day.
Galloway quoted Winston Churchill, “First we shape our dwellings, then they shape us.” The idea is that we set our culture and then it shapes the overall focus of the company. The key is to reinforce positive behavior.
He drew a circular diagram for the chemistry of safety cultural excellence: vulnerability->communication->measurement->passion->focus->expectations->proactive->accountability->reinforcement
Maturity Index for Machine Safety
Ludwig addressed Rockwell Automation’s Safety Maturity Index. You can find a podcast interview on this topic on my podcast site, Automation Minutes.
The Safety Maturity Index delineates three focuses: Culture (Behavioral), Compliance (procedural), Capital (technical). Each focus contains four levels: minimize investment, attain compliance, cost avoidance, operational excellence.
The key point is that one of the first things manufacturers need to do is to pay attention to developing a safety culture.
by Gary Mintchell | Oct 28, 2015 | Automation, Safety
The EHS Today Safety Leadership Conference is this week in Greenville, SC. I’m there following the Safety Technology track sponsored by Rockwell Automation. I’ll have reports on information from the sessions in a later post. Rockwell used this opportunity to recognize the winners of its Safety Excellence Awards for leadership in manufacturing safety.
Rockwell Safety Excellence Awards Winners 2015
Four organizations received awards at this the third annual Manufacturing Safety Excellence Awards. The company recognized The Clorox Company, The Goodyear Tire & Rubber Company, Kimberly-Clark Corporation and Paper Converting Machine Company (PCMC) for their leadership in applying a holistic approach to safety maturity across their organizations.
“This year’s recipients display a true commitment to safety maturity across their organizations,” said Mark Eitzman, safety market development manager, Rockwell Automation. “They’ve gone beyond approaching safety as a means to maintain compliance, and are embracing it at every level to achieve overall business goals.”
The Manufacturing Safety Excellence Awards honor companies that make workplace safety a core business value by building a comprehensive program based on three key pillars: a strong safety culture, well-executed compliance procedures, and effective use of contemporary safeguarding and automation technology through capital investments.
Following are the details about the award winners:
The Clorox Company: Tracy Glover, Jeff Deel, Rockwell’s Mark Eitzman
The Clorox Company
Clorox makes collaboration between engineering and EHS inherent in every safety project. Safety has become ingrained in the company’s culture. “Safety became part of our global company culture when we labeled it a core value, instead of just a priority,” said Jeff Deel, electrical instrumentation and controls engineering manager, Clorox. “Priorities can change over time, but our values remain constant. While we’ve seen improvements in productivity, throughput and competitiveness, the real focus is on ensuring that our partners and employees are well taken care of.”
The Goodyear Tire and Rubber Company: Dennis McGavis and Rockwell’s Mark Eitzman
The Goodyear Tire & Rubber Company
Global tire manufacturer Goodyear has taken a proactive approach to safety by creating a corporate culture that values the wellness and safety of its employees. It continually drives toward a goal of zero incidents and injuries. To help achieve this, engineering and EHS teams in manufacturing facilities around the world collaborate during all stages of introducing any new or retrofitted equipment or plants – from the design phase until final sign-off by the EHS team.
“When it comes to safety, compliance and regulations are certainly important. But in order to reach our target of zero incidents and injuries, we believe it is critical for our associates to make safety a personal value in their lives,” said Mike Porter, director of global EHS, Goodyear. “We’re very proud of the progress we’ve made with safety, but know that it’s a journey, and we’re committed to getting better every day.”
Kimberly-Clark: Peter Shen with Rockwell’s Mark Eitzman
Kimberly-Clark Corporation
Kimberly-Clark has a long-standing commitment to safety improvement and the health of its employees as one of the founders of the National Safety Council. “Safety is fundamental to our organizational DNA,” said Dennis G. Averill, CIH, CSP, global director of safety and hygiene, Kimberly-Clark. “We achieve success with everyone in the organization working and learning together, including engineering, EHS and operations. This collaboration is not only done conceptually, but also during the actual execution of risk assessments, safety standards development and more.”
The company also continues to achieve safety improvements through its R.E.A.L. strategy, which addresses safety from all angles, including risk mitigation, EHS management systems, accountability and leadership.
The Paper Converting Machine Company, Jill Thiede, Jason Stover, Rockwell’s Mark Eitzman
Paper Converting Machine Company (PCMC)
As a manufacturer of tissue converting, packaging, envelope, nonwoven and flexographic printing technology and machines, PCMC has made functional safety an integral part of its machine design process. “We differentiate ourselves from competitors by guiding our customers through the safety process and educating them on the opportunities safety presents,” said Jason Stover, senior electrical project engineer, PCMC. “Some might not recognize safety as a fundamental part of the equipment, but by the time we’re done, they see the value.”
Past winners
The 2015 Manufacturing Safety Excellence Award recipients join a distinguished list of companies that have been recognized as safety leaders. Past winners include Bevcorp, Corning Environmental Technologies, General Motors, Procter & Gamble and the PepsiCo divisions of Walkers Crisps and Pepsi Flavors.
