Awplaybook v4 PDF
Awplaybook v4 PDF
Awplaybook v4 PDF
PLAYBOOK
The bottom line for key automation
issues for discrete, batch process
and continuous process industries.
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TABLE OF CONTENTS
SECTION 1
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TABLE OF CONTENTS
SECTION 2
Batch Processing
65 9 Tips for Achieving Balance in Recipe Management
68 How Reusable Code Streamlines Recipe Management
72 10 Commandments for CIP Design
74 Top Recommendations for Designing and Using Skid-Based Equipment
77 Agreeing on OEE
82 Safety: The Lifecycle Approach
88 Conducting a Risk Assessment
90 How to Avoid Mistakes With Control System Remote Access
94 Options Analysis Tool for Remote Equipment Access
95 4 IT Standards You Should Understand
97 Tips for Dealing With Wireless Latency and Bandwidth Issues
99 Achieving Sustainability Excellence
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TABLE OF CONTENTS
SECTION 3
Continuous Processing
106 8 Ideas for Successful DCS Implementation
109 PLC vs. DCS: Which Is Right for Your Operation?
112 Procedural Automation for Greater Safety and Productivity
115 13 Suggestions for Control System Migrations
118 Managing for Reliability Key to Asset Performance
120 Measure First to Improve Control System Performance
124 10 Steps to Creating the Perfect HMI
127 Practical Tips for Implementing Intrinsic Safety
131 Wireless Sensor Applications
133 Managing Emissions With Automation
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INTRODUCTION
By Aaron Hand, Executive Editor
The Automation Playbook is a useful source of information for all industries as you
look for guidance in how to approach the Industrial Internet of Things (IIoT), new
communication protocols, control implementation, safety, asset management,
predictive maintenance, a mobile workforce, and so much more.
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SECTION 1 Factory & Machine Automation
Placeholder
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The following experts
SECTION 1 Factory & Machine Automation CONTRIBUTORS
contributed to this playbook:
Robert Lowe
Executive Director
Control System Integrators Association (CSIA)
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The following experts
SECTION 1 Factory & Machine Automation CONTRIBUTORS
contributed to this playbook:
Michael Mikolajczak Jad Wehbe Jim Hulman William Wang Kurt Wilde Tom Jensen
Bryan Sisler Automate, Lebanon - Joaquin Ocampo DuPont China, China Henniges Automotive, USA Lenze, USA
ABB, USA Germany - Qatar Bosch Rexroth, USA
Tim Matheny Satish Samineni Stefano Linari
Alex Miller Rafael Arevalo Duque Larry W. Ostrander ECS Solutions Inc., USA Halcrow, Qatar Linari Engineering srl, Italy
ABB Robotics, USA Automatizacion Ingenieros CADD Tech Support, USA
Especialistas sas, Colombia Ed Nachel Tianshun Qiu Dan Perkins
Mike Berryman John F. Wozniak Elobau Sensor Technology IBM (China) Co. Ltd., China LINAK U.S. Inc., USA
Advantech, USA Peter van den Berg CC-Link Partner Association, Inc., USA
Avans University of Applied USA Alexander Pinkham Jagjeet Paul
Wendy Jacintha Science, the Netherlands Julian Martinez ICONICS, USA Little Systems, India
AFLAC, Canada Johnny Sorensen Emerson Network Power,
Stanley Moses Chr. Hansen, Denmark Colombia Joel Albert Ken Lauer
Leslie Crothers Bahwan CyberTek Inc., USA Industrial Networking Middough, USA
Almac, United Kingdom John Lewis Roy Adams Solutions, USA
John Malinowski Cognex Corp., USA ERA LLC, USA George Hockett II
Rob Cotner Baldor Electric Company, Josu Bilbao Miniature Plastic Molding
Anixter, USA USA Mohbat Tharani Vikram Kumar IK4-IKerlan, Spain LLC, USA
COMSTATS Institute of EZAutomation, USA
Carl Stelling Shawn Day Technology, Pakistan John Wilson Deana Fu
Antaira Technologies, USA Henry Menke John Holmes Integrated Automation, Bryan Knight
Balluff Inc., USA Hernan Gardiazabal Festo Corp., USA Australia Mitsubishi Electric
Lonnie Purvis ContrALL, Mexico Automation, USA
Apex Manufacturing Jeremy Jones Robert L. Fischer Sudhendu Banerjee
Solutions, USA Baumer Ltd., USA Mike Cerda Fischer Technical Services, Instrumentation Ltd., India Stephen Chilton
Control M Automation, USA Monozee Ltd., United
John Coetzee Jingxu He Mexico Majid Takabi Kingdom
Aristotle Consulting, South Bayer, USA Eric Esson JGC Co., Iran
Africa Sanjay Mishra Frommelt Safety Products, Todd Desso
Mike Fahrion COTMAC Electronics Pvt. USA Tom England Eddie Lee
Sujata Tilak B&B Electronics, USA Ltd., India Kollmorgen, USA Mike Werning
Ascent Informatics Pvt. Ltd., Chris Alexander Moxa Americas, Inc.
India Eric Byres Roy Greengrass Givaudan Flavors, USA Pierre Lampron
Mike Miklot Del Monte Foods, USA KSH Solutions Inc., Canada Nelson South
Dave Robinson Belden, Inc., USA Dr. Colin Harrison Nelson South Electrical,
Aurora Industrial A. Klemptner Glasgow Caledonian Chris Weigmann Australia
Automation, USA Abdulilah Alzayyat DTE Energy, USA University, United Kingdom Lakeside Manufacturing, USA
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The following experts
SECTION 1 Factory & Machine Automation CONTRIBUTORS
contributed to this playbook:
Kenn Anderson Mark Battisti Gilbert Brault Jim Anderson Matthew T. Seiman Charlie Norz
Nova Systems Inc., USA QPoint Robotic Solutions, Antonio Chauvet Jill Oertel Trelleborg Sealing Solutions, WAGO Corp., USA
USA Schneider Electric, France Aaron Schulke USA
Joe Sebastian SICK, USA Nathan Schiavo
Diane Trentini Dennis Sanchez Johan Hult Ed Novak Wesco, USA
Optimation Technology Inc., RECOPE, Costa Rica Schneider Electric, Sweden Tom Hoffman Trio Motion Technology, USA
USA Jeff Miller Wilfredo Jimenez
Cheng Xinping Robb Dussault Gregory Richards Pramod Parikh WJ Automation & Integration
Ben Orchard Rockwell Automation, China John Boville Siemens, USA United Phosphorus Ltd., India Corp., Puerto Rico
Opto 22, USA Schneider Electric, USA
Chris Brogli Tomaz Vidonja Fernando Jimenez Karen Leung
Scott Klages Paul Brooks Jerry Schultheis Simplysens, Slovenia Universidad de los Andes, Worleyparsons, USA
Parsec Automation Corp., Douglas Henderson Schultheis Automation Colombia
USA Jimmy Koh Control Systems Inc., USA Mark A. Erickson Erik Nieves
Amy Peters Skills Improvement Inc., USA Alejandro Pena Yaskawa Motoman Robotics,
Mark Huebner Fatime Ly Seymour Eder Mathias Universidad Distrital, USA
PBC Linear, USA Thomas Sugimoto SEW-Eurodrive, Brazil Pat Gallagher Colombia
Rockwell Automation, USA Solar Automation Inc., USA Will Zurkan
Jose Gonzalez Valero Nesko Kontic Gary Phillips Zurkan Solutions, USA
PEMEX, Mexico Mahendra Dissasekera SGS - Wind Energy Lewis Gordon URS E & C, USA
Ronan Engineering Co., USA Technology Centre, China Tangent Services, USA
Helge Hornis Bill Bobbitt
Pepperl+Fuchs, USA Sam Shorer Shamsol Shamus Peter Hook Van’s Aircraft Inc., USA
SABMiller, South Africa Shamus Technology Ent., Tech Innovations LLC, USA
Mark Buckley Malaysia Sachin Kumar
Phoenix Contact, USA Andrea Sammartino Dave Szurek Vertex Automation System
Saipem Spa, Italy Dr. Gyan Ranjan Biswal The Mackubin Group, USA (P) Ltd., India
Rahul Aggarwal Shiv Nadar University, Noida,
Prekar Services & Solutions, Steve Sarovich India Assaf Beckman Pradeep Soni
India Sardee Industries Inc., USA Tomatic, Israel VSM Venture Control System
George Pease P. Ltd., Noida, India
Rafey Shahid Show-Me Machine Works,
Qanare Engineering, Pakistan USA
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The following experts
SECTION 1 Factory & Machine Automation CONTRIBUTORS
contributed to this playbook:
Algeria India Lithuania Saudia Arabia Greg Fairchild Stephen A. Sajewicz
Nesrine Chaouche Rajesh Keswani Genadij Nesterenko Ghulam Rasul Irene Farquhar William Schmidt
Sarang Kulkarni Spain Marty Grimes Accounties Smith
Bosnia Senthil Kumar Mexico Antonio Anton Tony Guzman Konstantyn
Bojan Djurdjevic Arunnun Loganathan Jorge Loza Miquel Vall Boladeras Daniel Hood Spasokukotskiy
Mukesh Negi Mark Huebner Joe Staples
Brazil Avinash Patil Netherlands Sri Lanka Joseph Kolo Jim Tennant
Edson Gonçalves de Oliveira Naveen Kumar Ramasamy R. Hulsebos Suren Stambo Rajendera K. Kapoor Suresh Vasan
Babu Reddy T Hindrik Koning Michael Kinziger Leonard Walsh
Canada Taiwan David Lamb Nick Wisniewski
Ed Kinakin Iraq Nigeria Jin-Mu Lin Todd LaRoche
Amer H. Rasheed Oladapo Akinbola Iyedupe Hian Yong Leong Venezuela
Guatemala USA John Nix Juan Nicolaidis
Moises Yac Ireland Norway Don Baechtel Tim O’Brien
Joe Burke Rune Saetre Jim Brastauskas Tony Olivieri
Egypt Michael Bowne Tony Paine
Mahmoud Abdel Fatah Israel Pakistan Daniel Bruno Tony Perna
Abo Ahmed Victor Zaltsman Faisal Mirzam Bruce Centofanti Friedrich Purkert
Marc Emmerke Ray Royal
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Here are five issues industrial organizations should consider 3. Location/environment: Where is your facility located? If
before making any moves: your equipment is in a remote location, can your devices be
monitored via cellular networks? Are 3G or 4G/LTE networks
1. Legacy equipment: Take inventory of automation devices such available to reach your site? If not, are broadband or fiber-
as PLCs, RTUs, robots and drives. How old are they? Do they based networks available? Also, within the building itself, what
need to be replaced or upgraded? Is your legacy equipment going is the overall environment? Is it hot and dusty or kept at a
to be able to communicate with newer equipment? How much controlled temperature? Is there lots of vibration? Are you
time and money will this take? What cost-effective solutions can using industrial-grade equipment that is designed with wide
address your current infrastructure? environmental ratings and industry certifications?
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before, with many unable to survive the economic turmoil. 8. Take a long-term view. Select an integrator with experience
Many integrators have reduced staff, minimized technology in similar systems, preferably of the same make. Tie payments
education opportunities and made other cutbacks. Take the to project milestones. Make sure his services will be available
time to assess the strengths and weaknesses of any integrator for upgrades and maintenance by signing a separate contract.
you consider to ensure that they are capable of delivering the
system that you require. 9. Problem-solvers. Choose an integrator who has experience
in the tasks you need performed. They have probably already
7. Stay involved. Has your system integrator done something solved many of the problems you may face if you choose one
similar before? Chances are the pool of talent isn’t all that whose experience is outside the necessary area of expertise.
big. Can you allocate any resources to working with that
integrator on a day-to-day basis? You will have to take 10. Ask questions. Choosing a system integrator is the hardest
ownership of the system, so you will need to know how to and easily the most overlooked part of an automation project.
modify it and maintain it or you will be tied into a system Ask questions about types of projects they’ve done, vertical
that might need unallocated cash to make changes. Get preferences and size of projects. Have them include project
involved at the zero level in the planning, simulation, detailed details, such as were they on time and on or under budget,
layout, software handling techniques and maintenance and what percentage of the time.
requirements as much as you possibly can in order to get the
biggest possible benefits and to learn in excruciating detail 11. Experience has its limits. Be aware that most integrators
how it all goes together. have experience either in a vertical industry or with a certain
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type of project, such as PLC/HMI programming. Either way, 15. Do they have business skills? Look beyond technology
they may lack the capabilities needed to do projects outside expertise or project experience to consider an integrator’s
of that experience. Many HMI/DCS vendors have a list of commercial qualifications: Are they CSIA certified? Do they
endorsed or recommended system integrators on their home have insurance? How many years have they been in business?
page. This is a good place to start.
16. Are they open? Select an integrator that is open to your
12. Smart isn’t enough. Choose an integrator as you would requests and ideas. Beware of someone that constantly
choose an employee. Spend time, talk to references and know
that while every firm out there enlists very smart engineers,
you don’t want them cutting their teeth on your project.
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pushes back. If you hear the phrase “nobody does it like that” because this is your first time. Also allow for the ability to
or “this is how everyone does it,” you might want to consider make some changes—especially if your approach is new and
another integrator that is more open minded. You are paying unconventional. Be open for changes and tweaks as you go
that integrator to get what you want and need—not just what if it makes the end result easier to use and more flexible. You
they are willing to build because it’s easy or they “always do it need to stay involved throughout the whole process. Don’t
that way.” Yes, you hired them for their experience and would pass up the learning opportunity!
like their suggestions, but don’t discount your own ideas just
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the technical staff, the repairs or adjustments will be met with resentment 5. Don’t forget the grounding.
and most likely extended downtime. 6. Don’t propose a project without a good
understanding of the requirements. That
6. Handshakes critical. Not paying attention to handshaking signals and guarantees scope creep.
improper use of I/O handling can cause serious damage to equipment, 7. Don’t always believe what salesmen tell
eventually causing more downtime. When two machines need to work you. Do your homework and make your
own decisions for your application.
together, it is critical to use appropriate handshaking signals to avoid any
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cell or machine damage. Bypassing safety is another cause for updated. That includes operators, technicians and production
problems. Design cells so workers cannot bypass safety measures. management. People might disagree on what has been
accomplished and what still needs to be done.
7. Experts inside. In-house expertise is essential to the
success of any project. Integrators build good machines 10. Can a machine do the job? If the automation project is
and systems, but when they are deployed in the plant based on replacing labor, you will first need to understand
environment, it’s the in-house expertise that turns a good the totality of what is being done manually. You may need to
system into a great system. go back to the drawing board if a machine cannot do what an
operator has been doing.
8. Plan for changes. When designing, or budgeting for
automation projects, usually there is a clear goal or list of 11. Limit program access. Always run an information session after
things that need to happen. But you also need to plan for the commissioning to familiarize all personnel who may be involved
unforeseen. Something will always come up later on that will with set-point changes, principles of operation, etc., and use
need to be added. To cover this, always add 20 percent to the password protection to allow set-point changes only within a
overall project budget. Also, additional checks or sensors may specified range. Never allow full access to program changes.
be needed down the line, so make sure you have extra I/O or
at least the flexibility to expand the I/O if needed. 12. Forbid coding from Day 1. Automation engineers love to
puzzle with the problems they get on their table. Forbid any
9. Do a punch list. After initial implementation, get agreement use of coding software until the entire scope is clear and
from everybody on the punch list of items that need to be closed, the delivery has been broken down to manageable
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• Selecting low-cost components to meet a budget. 16. Avoid complexity. You’ll make life complicated by
introducing complexity into the operation, so that what’s
• Errors in lead-time calculations. implemented at the site is not what was conceived of in the
design. Many times simplicity is ignored when designing
14. Will it save money? Being able to automate a process controls. What may be friendly to one smart operator can’t
often leads to the mistaken belief that it will result in a less be generalized for all operators. Refrain from tailoring the
expensive process or product being made. This is frequently controls too much. Suggest cost-effective and competitive
due to a poorly executed cost/benefit analysis. solutions when they already exist.
15. Vendor cautions. Vendors can be great resources but 17. Garbage in, garbage out. People tend to assume that the
they are poor manufacturers. They often lack a complete person coming in to do the automation work will just pick up
understanding of all the factors involved, not only the on what is being done at the plant and how things work. Good
installation of the project but the operation, repair and user and system requirements are a must for any project.
maintenance of the project. The vendor is a servant, not an The final automation system will only be as good as what you
executive. Research vendors carefully and talk to others who ask for in the requirements document. Without well-defined
have used the vendor. Caution is particularly called for if you objectives, you will get scope creep.
are designing or in charge of a project where some of the
technology, software or application use are unfamiliar or new. 18. Document everything. A small change requested by the
customer often leads to other changes that are much more
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costly. If you don’t have paperwork showing the requested of functionalities, in a limited and controlled part of the
change and costs, it will be difficult to bill for the work. production process. As soon as possible, do a trial using real
data. Don’t design a system that, if it fails, would completely
19. Consider more than cost. Too many companies allow stop or seriously impact the production process.
dollars to determine what types of equipment to install. They
also fail to find out whether local support for the equipment 22. Plan for maintenance. We should not install anything if we
will be available. You must be able to source both hardware have not planned properly for maintenance. Proper system
and software within a time frame that suits the client. maintenance is a must.
20. K.I.S.S. Some programmers go far above and beyond the 23. Listen to the experts. Among the most common
necessary when it comes to programming. Try to keep in mind the problems, from a manufacturer’s perspective, are:
individual at the factory level who has to support this system after
the integrator is gone. They do not see high-level programming • Failure to ask for help early.
on a regular basis and will struggle mightily at trying to decipher
logic that is much more complicated than it ever needs to be. • Not following manufacturers’ suggestions.
While there are times when complex programming and high
level functionality are called for, most projects need to apply the • Not investing at least a minimum amount of time in training.
K.I.S.S. rule when the system is being developed.
• Making assumptions that turn out to be wrong, and thus
21. Start small. The best way to ensure long-term success ultimately wasting a lot of time.
is to think (plan) big, but start small with a limited number
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NO SHORTCUTS
There are no shortcuts in automation projects. THE FUTURE OF MICRO PLCS
To estimate time and costs for a project requires Technology that evolves with your application
seriously taking into account the skill levels and
experiences of employees. The hardware design
is usually the easy part. Software specification, To handle your most demanding tasks, you not only need
a controller that can do the job efficiently and reliably, but
programming, testing and, commissioning are much also expect it to have the most advanced communication
more difficult tasks to estimate. If the available and IIoT features. The new IDEC MicroSmart FC6A Plus
micro PLC offers cutting-edge features, suited for today
employees for the projects are not familiar with but adaptable for future applications so you stay a step Built-in Analog
SD Memory
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6. Do you need flexibility? PC-based controllers not only lend themselves • Plug-ins and 2085 expansion for I/O USB.
to customization, they support it over the lifetime of the equipment. • Single programming software package
that eases installation, configuration,
connectivity and maintenance.
7. Got the need for speed? In general, a PC-based controller will be
faster than a PLC.
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intelligent overload that has motor load feedback (alarm back 8. Beat dust with magnetic coupling. For variable-speed control
to operator as well as shutdown parameters) with a hybrid of rotating equipment, such as drives for an agitator motor or
contactor. The hybrid contactor extends the time between a chiller compressor, take special care to place the drive in a
end-of-life motor switching by a factor of 10. The intelligent hardware panel installed in a dust-free location, preferably air-
overload will remain in service indefinitely. conditioned. A better solution for harsh environments that have
maintenance people with minimum skills might be a magnetically
6. Consider VFDs. Instead of operating an AC induction motor coupled drive with variable-speed option. Magnetically coupled
at top speed and adjusting the speed of the load mechanically, drives have the advantage of decoupling vibration and potential
for example with a control valve, consider a variable- overloading of the motor or driven equipment due to the air gap
frequency drive (VFD). It will save energy and prolong the between the motor shaft and the other shaft, which can reduce
lifetime of the motor. It will also eliminate the need for a costly damage to mechanical seals.
valve, reducing costs, points of failure, and maintenance.
Examples include include pumps, fans, and blowers. 9. Focus on economical sparing. Avoid the temptation to size a
motor separately for each axis. Try to standardize motors and
7. Do your homework. Always check for the proper rating drives around a few sizes. This will minimize your spares inventory.
and proper type of drives or motors for different type of Also, instead of stocking multiple spare cards for the drive, keep
application. Ask the supplier about the fail-safe function of one spare module. This will be an economical solution.
the system and always check for proper grounding of the
system. Make sure you inform the supplier about the features 10. Avoid common drive pitfalls. The reliability of the core
you want and the process to be controlled. components, such as the PLC or a variable frequency drive, in a
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HOW DO LEADING MANUFACTURERS
USE VISUAL COMPONENTS TO EXCEL?
SECTION 1 Factory & Machine Automation
DESIGN SMARTER MANUFACTURING SOLUTIONS
CONTINUED 12 Guidelines for Selecting Design smarter solutions and get better outcomes with
technologythat’s purpose built for manufacturing design.
Motors and Drives GET PREDICTABLE PERFORMANCE
Plan new projects with confidence. Reduce critical
control system is important. Drive failure may be caused by mistakes and oversights and get results that you can trust.
many factors: PCB calibrating, IC chip failure, mishandling
VALIDATE CHANGES VIRTUALLY
during installation, operating environment, etc. Even Design, test, and simulate changes in the virtual world
though the manuals of some drives claim that using certain first. Minimize downtime and speed up implementation.
11. Try manual mode. The manual mode, which allows maintenance
to check if one specific motor has a problem or not, is usually
forgotten. If the motor will not run correctly, put the drive into
manual and run the motor for a short time. This eliminates the
drive from the problem and points to the controller or, if local
control does not work, the drive could be suspect.
12. Aim for good housekeeping. Keep motors and drives clean
and free of foreign contaminants to keep them running for a
long period of time. Don’t use the cord as a leash when you are
carrying the motor around.
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often be a barrier to achieving the cost savings and efficiency your application so that tooling does not damage in-order
gains expected with robots. production parts. Selecting a well thought-out end effector
will also help minimize the teach time on the final program
5. Tooling clearance. It is very important to have a clear, to ensure the proper clearance to run the robot at the
defined understanding of the type of end effector for maximum speed.
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6. Plan for maintenance. For large issues. You may find that there is
robots, make sure means for more going on in the existing process MECHATRONICS FOR OEMS
maintenance are included in the than you knew about and that micro- The perception of robots in the
original project scope. A monorail management is necessary. industrial workplace follows a form
hoist designed in at the start of factor that leads users towards a limited
amount of mechanical models. This
the project, for example, is much 8. Zoning for product size. In a
feels modular, but it’s not mechatronic.
cheaper and easier to install than robotic pick-and-place system for Changing the definition of robotics
one built years later. Installing a hoist thermoformed packaging trays, to coordinated axes synchronized
while running requires scheduling, incorporate zoned suction cups that by a single software and processor
opens up conventional machine design
downtime, lost production, etc. can be isolated or turned on and off, to modular code and mechanisms—
Installing a hoist during emergency to allow for various tray sizes. or mechatronics. OEMs that have
maintenance never happens, and adopted this new outlook make robotic
machines that are faster, smoother
temporary, sub-optimal, rigging ends 9. Electronic changeovers.
and more flexible, not by changing
up hurriedly being used. Customization is only a fraction their mechanics but by changing their
of the normal line production, but approach. The choice for OEMs is even
7. Get early feedback. Try and do as the ability to create electronic easier because they need only migrate
their control philosophy to those
detailed a simulation as early as you changeovers between formats in capable of true mechatronics.
can and show it to the workforce a small footprint streamlines the
involved in the process in order to customization process.
get feedback on possible operational
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Ethernet because they want to fully benefit from Ethernet 7. Speed issues. It is important to understand that the
and its higher-level functionality, such as web server, operating frequency of the core switches will determine the
diagnostic, firmware upgrade, etc. speed (throughput) of your network. Educate yourself on
switch and network compatibility issues. Your network is only
4. Learn Ethernet. Take the time to learn (through courses or as fast as the weakest link. Just because you’re using Cat.
self-taught) the art of Ethernet networking. It’s never going 6 patch cables doesn’t mean that your permanent cable or
to go away. If you can seamlessly work through VPNs, port connector is rated for 6.
forward, subnet masks and IP addresses, your job is only going
to become more interesting. 8. Network slowdowns. Most network audits revolve around a
slow or degrading network as new devices are added. The lack
5. Get ready for connectivity. It makes sense to implement of fundamental understanding of Ethernet architectures is the
all PLCs on Ethernet using protocol converters. This makes most common cause of these issues. Prior to deployment of an
your plant ready with data available on Ethernet for future Ethernet-based control system, spend time understanding the
connectivity with MES/ERP systems. data impact of additional devices. It’s also essential to spend
time training staff on Ethernet and associated protocols.
6. Choose fiber. For Ethernet networks, be proactive
about choosing fiber over copper for primary connections.
Distance capabilities, noise immunity and immensely scalable
bandwidth will pay off quickly.
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a custom JSON or binary format. MQTT isn’t as widely used plate calibration coefficients might be useful from a SCADA
as HTTP, but it still has a large market share in IT. There are or manufacturing execution systems (MES) standpoint.
many open source clients/producers, brokers, projects and Because operations is already polling that device for the
examples in every language. flow rate data, however, adding more polls will not only be
complex, it will also upset the plant-floor polling cycle.
4. Know the sweet spots. Use HTTP for sending chunks of
data, like one-minute temperature readings every hour. Don’t MQTT helps prevent polling problems by having the
use HTTP for streaming high-velocity data. HTTP can do plant floor device transmit all its data to an MQTT server
sub-second data, but 100-ms updates over HTTP are difficult. on a constant, real-time basis. Then you connect your
It has a lot of overhead per message, so streaming small applications—as many as you want—to the MQTT server. You
messages is inefficient. can access whatever data you need from the device without
connecting directly to the device itself, thereby avoiding any
Use MQTT when bandwidth is at a premium and you don’t know effect on its operation.
your infrastructure. It focuses on minimal overhead (2- byte
header) and reliable communications. It’s also very simple. 6. Get in a state. Unlike HTTP, which is stateless, MQTT has state.
That makes it well-suited for use in a control system environment.
5. Avoid polling problems with MQTT. That flow computer
doesn’t just generate flow rate data. Other information from 7. Keep it protected. Always secure HTTP communications
that device such as end-of-batch tickets, audit trails, orifice- using HTTPS.
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DESIGN, OPTIMIZE, VISUALIZE
SECTION 1 Factory & Machine Automation THE FACTORIES OF THE FUTURE
With Visual Components 3D Manufacturing
CONTINUED Guidelines for Using HTTP Simulation Software
and MQTT Protocols
Layout Planning
8. Build your infrastructure. If you are using MQTT, make sure you
Production Optimization
or your vendor have an MQTT broker you can publish data to—and
PLC Verification
always secure communication via Transport Layer Security (TLS).
Offline Programming
Virtual Reality
9. Be aware of interoperability issues. Just because two products
support HTTP/REST/JSON doesn’t mean they’ll work together
out of the box. Often the JSON formats are different and require
minimal integration to get things working. Similarly, just because two
applications support MQTT doesn’t mean they are interoperable.
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7 Safety Functions
That Can Save You Money
There was a time safety meant electromechanical relays 1. Safe Torque Off (STO): Removes power to the motor but
that cut power to the equipment anytime an operator hit leaves the drive energized. This puts the equipment in a safe
the e- stop button. Although this was effective, it was hard state while making it faster and easier to restart.
on equipment and often more extreme than circumstances
warranted. Frequent stops cause premature failure in the 2. Safe Stop 1 (SS1): This controlled stop enables equipment
safety relays. Restarting equipment added delays and to be slowed before STO is invoked. It is an active braking
extended costly downtime. operation that can safely and more effectively stop equipment
with high kinetic energy.
Today, the modern crop of safety standards such as EN/
IEC 62061, EN/ISO 13849-1 and IEC61800-5-2 enable 3. Safe Operating Stop (SOS): Drive holds motor in a static
equipment to invoke safe states as defined by the function position to within a certain tolerance defined for the drive.
of the system. This functional safety is implemented by Torque to the motor is not removed; the motor is just held to
safety-enabled drives and PLCs. Functional safety makes it zero speed.
possible to protect workers and equipment while minimizing
the impact of those measures on operating costs and 4. Safe Stop 2 (SS2): Controlled braking ramp, once again,
productivity. Here are a few of the key safety functions that suitable for equipment with high kinetic energy. SS2 is
you should know about: typically followed by SOS, rather than STO.
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CONTINUED 22 Ways to Get the Most Out of OEE and Lean Manufacturing Disciplines
What they fail to do is penetrate the details of why it Among the most useful KPIs to display: count (good or bad),
worked, what support structure is required and how that reject ratio, operating speeds, takt (cycle) time, downtime and
translates to their internal business. Lean is as much about OEE (availability multiplied by performance and quality) for
management engagement in daily operations as it is about determining resource utilization.
the methodology.
6. Increase uptime. Lean manufacturing is a very important
4. Measure the right things. Nothing is worse than the wrong factor in a production plant. Just by placing materials at the
input. OEE is not always a KPI metric in batch operations. If you point of use within the production floor area, you can increase
speed up the drying process, for example, the OEE goes down, production uptime. This is just one small adjustment that will
but you will be making more product in a shorter period of time. fine-tune the flow of your product.
5. Visual management. Visual management, including large 7. Too lean? If you operate with vendors that are stationed in
display screens on the factory floor, are an effective tool areas with a high potential for natural disasters, think carefully
for OEE programs, letting both managers and workers about being too lean with your supplies. You’ll need to plan
easily monitor the metrics of production lines and track for alternative routes and suppliers. Another area that has to
KPIs. Displays harness natural human competitiveness. In be monitored is the amount of time for production to meet
one experience, once data was displayed it started a race customer need. Sometimes manufacturing is too lean and
between shifts to drive up OEE. Without any management when there’s a sudden demand, the slow ramp to manufacture
intervention there was a 20 percent increase in productivity. can cost more money than producing stock.
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8. Business support. Make sure the business has adopted availability, speed and quality, and how to calculate each.
and fully understands OEE. This can be a huge change Once processes are stabilized, use OEE to drive improvement.
management nightmare if not well-entrenched prior to
the project (or as part of the project execution). Lean 11. Software less important. Software selection plays only a
manufacturing can also be applied to service disciplines, small part in the OEE process, but that is where customers
not just product manufacturing, mostly with only minor spend the most time upfront. Operator involvement, the
adaptations. Look to these techniques and principles to quality of the integration partner and the ability of the
streamline your own processes and eliminate waste. controls hardware to collect data are what truly make an OEE
project successful.
9. Meaningful reports. Data capture is quite easy. Reporting
the data in a manner that helps implement change can 12. Efficiency tool. OEE has to be automated to be successful.
be challenging. Don’t assume a single report is sufficient. The data needs to be driven from machine status, not humans
Different users need different data. And that data must be inputting the status. Any manually derived OEE system can be
presented to each user in a manner that is meaningful. fiddled with to produce the expected 85 percent efficiency
rate. Improving systems and automating OEE measurements
10. Improvement tool. OEE can be a very valuable tool to may bring into question the accuracy of historical OEE data.
identify problems within a process. Ensure that everyone To avoid internal politics, put an amnesty in place and promote
understands what the three elements are that make up OEE: automated data as a new way of measuring OEE. On the
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other hand, the only reason to use OEE is to help drive an installing or defining automation products in a production
improvement process to increase operational efficiency. If line, it is their capacity to share data across the enterprise
that isn’t a widely embraced priority, then save yourself lots of that is important. One of the major causes of failure when
time, money and effort. implementing an OEE project is the infrastructure of the
automation and inspection controllers (PLC, vision system,
13. Improving uptime. OEE can help you identify opportunities etc. ). Vision systems must be able to communicate openly
to improve your total uptime. First, understand the categories with other systems, such as OPC Server or databases. Avoid
that OEE represents. Next, determine what things you want the use of products that operate in a closed system and do
to track and how specific you want to be. There isn’t a set not provide a ready means to share data.
rule as to what that may be. An example may be that under
your performance efficiency category, you list specific pieces 15. Build on current infrastructure. Do not get over
of equipment in an assembly line to track. By breaking down complicated right from the start. Pick a system that leverages
your categories you will have better opportunities to make your existing automation infrastructure, and can be expanded
improvements. The last hurdle is how to capture the data used and built upon as your needs change in the future. Do one
to calculate OEE. Keep it simple and train your people in how machine, or one line, or one department, then refine it so that
to capture the data you need, what it is and why it’s important. operations, production, and maintenance all have the types of
information they need, then roll out to other areas.
14. Sharing data. Information is fundamental to making good
business decisions. However, the information must be precise 16. Maintain balance. Lean manufacturing sounds great
and the amount manageable, not overwhelming. When to accountants and plant managers, but the upshot of
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the theory can be destructive if not enough product 19. Common framework. When implementing projects
is produced or the lean process creates inefficiency. for OEE, the communications between systems needs to
Remember, there has to be a balance. be reliable, fast and easy to use and maintain. Ethernet
has become the standard in communicating data across
17. Make Lean work. Lean manufacturing is all about automation systems. The installed based, along with the
how an organization can reduce scrap and waste in the expertise already existing in most companies, make Ethernet
production process. Evaluate your flow process, such as the most appropriate choice. Avoid devices that use
where product is placed before the production area or how only serial connections (RS-232, RS-485) or proprietary
the product is transferred to and from the assembly line. connections. Try to select one industrial protocol based on
If your production line stops as a result of parts that are Ethernet. Even though there are some protocol converters
not properly staged on the line, you have a product flow and gateways that allow the conversion between protocols,
problem. This becomes a bullet point in making Lean work try to select a protocol that is compatible with most of your
in you plant and should be addressed. existing devices. Establish a long-range standard where all
your future automation equipment must be compatible with
18. Select a champion. When implementing these projects, the selected protocol. In this way, your infrastructure will
make sure there is an official project champion who is very provide the correct framework where your OEE project can
senior in the implementing organization and can be the bridge be easily implemented.
between staff and management. The champion will need to
drive the changes that will be needed to business processes to 20. Win over minds. The first place to start with OEE is not in
achieve a successful project. the machines, but in the minds of the individuals that the OEE
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information is going to help. Without their buy-in the project 22. C-level needs. OEE is great for benchmarking and it works
will be no more than a pretty notice board. perfectly in theory. Many companies use statistical and not
real-time data from their production facilities to calculate
21. Vision drives OEE. Improved process efficiency and their OEE. Though OEE is easy to understand in theory, in
profitability through OEE improvements are increasingly practice there are many questions, especially how to properly
important. Machine vision systems and image-based ID calculate it if your manufacturing process often changes, is
readers help with three traditional OEE drivers: material dynamic or if some machines are used to produce different
handling, product quality and package integrity. Vision parts/products in the same shift. One solution is to use a
systems for sorting, product orientation and tracking, along simple wireless sensor network to monitor basic functions
with robotic guidance, improve material handling efficiency in real time and make a monthly C-level business report
and flexibility, elevate product quality and yield, and ensure based on real-time production data, which makes much more
package safety and integrity. In addition to these OEE drivers, sense then a detailed, heavy-to-read collection of graphed
machine vision inspection and image-based ID solutions information. This way you can adapt the OEE/lean process to a
address emerging brand protection and compliance drivers. company’s specific needs and understanding.
They form a key part of the foundation to support track and
trace, random mass serialization and traceability applications.
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OpX Leadership Network’s OEE Benefits Calculator helps production quantity. This will result in reduced direct labor
you find opportunities for increased efficiency on the plant expense related to fewer paid hours and reduced overtime
floor. More specifically, the OEE Benefits Calculator will help premiums.
you calculate the product cost impact of future performance
improvements and enable development and comparison of Raw Material Ingredient and Packaging Yield
various improvement scenarios. Unplanned stops on the production line result in scrap and waste from:
• Quality variation and rejects caused by instability in the
Savings obtained via OEE calculations are attained in two key areas: production process.
• Spilled, damaged or incomplete product that must be scrapped.
Direct Labor Wages & Overtime Reductions in unplanned stops will result in improved yield.
Improvement in OEE will enable a line to meet production
targets in fewer direct labor-crewed scheduled run hours. >> Download the OEE Benefit Calculator User Guide
So improved OEE could enable a reduction in the number
of weekend days that must be scheduled to meet the target >> Download the OEE Benefit Calculator Example
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2. Select the right tools. A comprehensive energy 3. Be focused. Concentrating energy improvement programs
management program is quite challenging, since every aspect on the high usage systems is usually the best place to start.
of a manufacturing facility is an energy consumer (processing, However, you can’t optimize what you can’t measure. Find an
packaging, warehousing, utilities and even the building itself). easy and cost-effective way to measure your plant’s power
A common mistake is to expect a traditional process or usage by area or major equipment group. Measuring without
machine automation system to be pressed into service for being able to time stamp data lessens the value of the data.
energy management applications (EMS). Don’t try to make
your existing software do the job. 4. Make it granular. The value of energy monitoring is to
gather enough data to truly understand what is happening.
Choose a purpose-built energy analytics package. It Placing meters on one or two motors will not give the results
will deliver results faster, in easily consumable form. you need. It is better to fully instrument a small area and
Customizable dashboards, make it easy to create displays concentrate on the results of that pilot project. You will
that deliver the information that different job roles can discover low hanging fruit that will help you gain support to
leverage to improve results. You want to be able to do more broaden the initiative throughout the plant.
than just view equipment demand is a function of time.
You want to be able to compare energy use from facility to Installing energy-monitoring equipment is the first step in
facility, line to line, machine to machine, even operator to enabling true energy management for your plant or process.
operator. This will give you the data needed to:
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• Know where your energy is being consumed, in process and just production lines but facilities and building automation
non-process applications. equipment like fans and blowers, compressors and so on.
Data capture needs to be comprehensive in order to create a
• Determine schedules of use. full picture of your operation.
• Determine real energy needs. The exercise is quite likely to include some obvious culprits.
You may find compressors or pumps left running when
• Manage supply and consumption by schedule and percent by they should be shut down. You might discover equipment
shifting time and managing and shedding use. scheduled to be left idle running at full speed. You may find
machines with a second or two of title time programmed into
5. Be smart. Apply a current transducer to your load, whether each cycle. It’s all but impossible to distinguish by sight but
that is the incoming feed of a building, a line, a machine, or adds up over the course of a year.
even a motor. You don’t need all new smart components.
Adding sensors to your existing equipment will do just fine. 7. Keep it targeted. Data capture also needs to be strategic.
Monitoring a device just because you can is not just unhelpful,
6. Establish a baseline. Once you’ve targeted your first it’s counterproductive because all of that data clogs up your
project, establish a baseline. Gather data from your network and fills up available storage. Know how you are
sensors using a data logger. This should encompass not going to use the data before you ever acquire it.
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8. Break the process into three parts: Once you have the data, understanding your assets before you can make an informed
you need the aggregation and analysis tools to transfer it to a decision on what equipment to investigate for energy
relational database environment where it can be accessed for improvement programs. Purpose-built energy management
a range of operations. There are three levels of working with applications are available with preconfigured dashboards and
data: monitoring, analysis, and management. Let’s return to built in tools for trending and data analysis.
our energy example:
10. Track big consumers. Always make sure you have the
• Energy monitoring: What energy is being used and how? means to track the energy performance of large energy
consumers. The term “large” can be determined by using a
• Energy analysis: What are the peak consumers? How does simple Pareto analysis. Make a list of all of your energy users
energy usage change over time? and section off the top 20 percent. This will identify a large
portion of your energy usage, as well as the focus of your
• Energy management: Can we put rules and equipment maintenance activities.
in place so that when equipment exceeds thresholds, it
automatically compensates? 11. Manage idle states. Minimize energy draw during energy
savings idle process conditions.
To accrue savings, you need to follow through on all three.
12. Evaluate power quality. If you are investing in a system
9. Be patient. Although low hanging fruit is likely, expect to measure power usage, you should consider one that can
to spend several months establishing a baseline and fully also measure power quality. Poor power quality can lead to
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increased power consumption, as well as equipment failures. induction motor and control valve with a motor driven by a
Measuring harmonics in a system will provide you with very variable-frequency drive (VFD).
beneficial information and the additional cost for this feature
is relatively little. 16. Reap side benefits. Energy monitoring doesn’t just help
the facilities management department. Other areas like
13. Design for efficiency. When designing industrial equipment engineering can leverage the data to harvest insights that will
with pumps or fans, require efficiency of operation. A lot improve productivity and reduce downtime.
of energy is wasted due to over-design of this equipment.
Engineers often use the same pump-motor specification • Maintenance: Changes in power consumption by a piece of
across the plant. This can result in motors being as much as 50 equipment can reveal the need for maintenance well before
percent under-loaded in fan operations. the component fails.
14. Be a giver. Offer energy capacity back to the grid on • Engineering: Differences in power consumption between two
request in exchange for incentives. identical pieces of equipment can show the effect of different
settings, assembly practices, or maintenance procedures.
15. Go beyond electricity. Don’t forget factors like airflow,
temperature, and pressure. If you a drop in compressor • Operations: By comparing consumption shift to shift,
airflow, it could be a leak but it could just as easily be caused machine to machine, or even plant to plant, managers can
by an issue with a bearing or valves. If a process step mostly develop best practices or identify operators who need
uses low flow rates, consider replacing that fixed-speed AC additional training.
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ECONOMICAL WAYS TO
ACHIEVE SAVINGS
1. Use interns to collect data. It’s fairly simple to
identify viable energy management projects, but it
takes real engineering to develop the business case. If
you’re understaffed and strapped cash, reach out to
your local university. You may be able to hire an intern
to collect the actual data points needed to develop a
well-founded business case.
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In predictive maintenance, condition monitoring makes it With a few work process changes and a focus on information
possible to identify equipment issues before they escalate from intelligent measurement devices, companies can
to full-blown problems. Tracking energy consumption of an transition from preventive maintenance to conducting a daily
ordinary motor can turn it into a complex sensor. Abrupt predictive routine, dramatically improving plant operations
changes or slow increases can indicate a failing winding and reducing maintenance costs. Here are some tips for
or worn bearing before it becomes critical. In a pumping success in making the transition:
application, it could indicate clogged filters or dry running,
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1. Make the case: Begin keeping a log of unplanned 4. Become a history buff: Establish a database of performance
downtime, including details on duration and estimated metrics to delineate the boundaries of “normal” operation.
cost. This will help you make a convincing ROI argument. Through subsequent and ongoing performance monitoring
Review your existing equipment. You may already have and recording, small changes in performance that occur
functionalities such as networked components, data loggers, over time can be detected and investigated before there is a
and analytics software. downtime event.
2. Find a champion: Moving from reactive or preventive 5. Go digital: The 4-20 mA current loop might be the most
maintenance regimes to predictive maintenance requires a common sensor output signal, but it does not provide the
culture shift. Management support is essential to enacting breadth of information available from digital sensors. A smart
a maintenance culture that includes work processes that digital sensor not only delivers performance data, it can
facilitate the change. This change is more than just a store information like model number and serial number for
maintenance matter. tracking and identification. Some digital sensors allow users to
change parameters remotely, or automatically upload stored
3. Choose the right hardware: To be successful, predictive parameters at startup.
maintenance strategies require intelligent field devices, an
open communication protocol, and integrated device and 6. Tune out the noise: Predictive maintenance requires
asset management software. comprehensive instrumentation but the sheer volume of
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data from thousands of devices can be overwhelming. It’s a pressure transmitters on pumps for a 90% savings over
particular problem given that a large percentage of readings conventional wired devices.
report steady-state conditions. Use data loggers with
triggers to sift out anomalous readings. Look for purpose- 9. Open up: Several open standards groups have sprung up
built asset-management software and analytic software to support predictive maintenance with smart components.
designed to help prioritize information. Many of these The FDT Group AISBL, for example, promotes the open,
software suites include built-in application libraries and tools vendor-independent Field device tool (FDT standard to
to simplify building dashboards. simplify the configuration of and access to field devices. Each
device uses a vendor-supplied software application known as
7. Pick targeted tools: Determine the requirements for your a device-type manager (DTM), which automatically provide
particular application. The needs of an oil rig, for example, proactive device health alerts. Some DTM’s analyze the data
will be very different from a packaging line for consumer to determine probable cause and corrective action, both for
packaged goods. Look for niche solutions designed for the the device in the network.
specific use case of interest.
The Profibus and Profinet International (PI) organization
8. Consider wireless: Cutting the cord can simplify also supports manufacturing process control and asset
installation, cut costs, and reduce maintenance. One North management. Their approach is to leverage the diagnostic
American oil refinery installed wireless temperature and and alarm schemes built into the instruments themselves.
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is a process, not an event. Although you can begin collecting • 40 percent reduction in time spent on
data within minutes using some hardware and software tools, maintenance.
it typically takes three to six months before the system has • Savings of more than $52,000 per year.
sufficient history to enable truly effective asset monitoring. • Component replacement only when
indicated by conditions.
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BATCH
PROCESSING
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The following experts
SECTION 2 Batch Processing CONTRIBUTORS
contributed to this playbook:
Chris Bacon John Rezabek
Production Manager Process Control Specialist
Graham Packaging Ashland Specialty Ingredients
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The following experts
SECTION 2 Batch Processing CONTRIBUTORS
contributed to this playbook:
Bob Rochelle Juan Cuevas Tim Matheny
Food and Packaging ECS Solutions
Industry Specialist,
Staubli Corporation
Darrell Davey Henry Menke
Intelligent Measurement Balluff Inc.
Solutions LLC
Dave Woll
Vice President Devkant Gandhi Hector Re
ARC Advisory Group Inc. IQA
Herman Storey
Co-Vice Chair
ISA-108 Standards
Thanks as well to the many contributors
Committee
who wanted to remain anonymous.
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The following experts
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contributed to this playbook:
Control System Integrators Chetan Chothani Bryan Curtis, P.E.
Association (CSIA) President Senior Consultant, Power/
Automation World worked with Adaptive Resources Facilities Dept., Matrix
CSIA to gain access to the expertise Technologies
of its system integrator members
to bring you much of the content in
this playbook. Alan E. Lyon, P.E. Antonio Manalo
Lead Engineer Automation Systems Integrator
To become a member of CSIA, a
control system integration firm Avid Solutions Avid Solutions
must demonstrate experience and
commitment to the field. Members
who earn CSIA Certification have
passed an independent audit of Alex Palmer Dario Rossi
80 criteria covering all aspects of Team Lead Chief Engineer
business performance, including Aseco Integrated Systems Aseco Integrated Systems
general management, financial
management, project management,
quality management, supporting
systems, human resources and more. Scott Saneholtz, P.E. Robert Snow
To maintain their certification, CSIA Manager Senior Process Control
Certified members must be re- Process Solutions Dept. Engineer Optimation
audited every three years.
Matrix Technologies
For more information about CSIA
and its system integrator members,
Ronald Studtmann, P.E. Russel Treat
visit http://www.controlsys.org.
Associate Dept. Manager, Power/ President-CEO
Facilities Dept., Matrix Technologies EnerSys Corp
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protecting the intellectual property of these tangible assets. who often don’t understand the problems of programmers.
Have a safe practice to transfer the recipe from the nutrition Formalize recipe descriptions to avoid ambiguity in their
department to the plant. It could be wireless. Make sure it has interpretation by the programmers. It is very useful to
a buffer to keep the new recipe until the old one is done. simulate recipe-based processes to demonstrate the work
of the program that implements the specified recipe. After
4. Simplify changeovers. Follow ISA S88 standards for the first such demonstration for recipe authors, it is highly
quick and automated changeovers. Procedures are clearly probable that the recipe records will need to be changed.
defined and can be monitored. If a specific process
cell is troublesome, it can be isolated, analyzed and 6. Keep ingredients separate. Avoid contamination in any
corrected. The correction could range from rewording the changes that are made by keeping the ingredients separate.
procedure to improving the instrumentation or automating Form/fill/seal machines have to be cleaned thoroughly when
the process—all without requiring a facility rebuild. changing from one mix to another. Once changed, be sure
Miscategorizing CM, EM, phase and other values can make to run a batch for checking the components of the mix. Any
for long, cumbersome recipes or inflexible ones. The clues software changes have to take into account all the items
are in ISA-88 and ISA-106TR. contained in the original software.
5. Simulate programs. Control process recipes are usually 7. Database concerns. Recipe management software
developed by technologists who understand the processes but should be based on the dynamic of current standards
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Common process control language The standard sets forth a set of building blocks for process control
ISA-88 accomplishes this by defining a common language at all levels: enterprise, site, area, process cell, unit, equipment
for process control to improve communication between the module and control module. The three highest levels explain how
various players involved in controlling plants and production the standard’s language can interface with the business systems
processes. It also creates a structure with consistent concepts of the area, plant site and business enterprise as a whole.
and models for batch processes that provides a map for how
developers should organize their software code. The next two levels, process cell and unit, are the building
blocks of the production process. One or more units are
contained in each process cell. Each unit is a collection of
controlled equipment.
Universal structure
The standard can be applied to either simple or complex
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According to industry experts, users typically achieve a • Reduce a user’s time to reach full production levels for new
30 percent savings in programming time and costs for products.
the first project, and as much as 70 percent savings on
subsequent projects. • Enable vendors to supply appropriate tools for implementing
batch control.
Broad applicability
Industry experts say an estimated 50 percent of all U.S. • Enable users to better identify their needs.
manufacturing is now accomplished using techniques and
technologies consistent with the ISA-88 standard, which has • Make recipe development straightforward enough to be
been proven in thousands of applications and can be applied in accomplished without the services of a control systems
either DCS or PLC control environments. engineer.
The ISA-88 standard can be so widely applied because its • Reduce the cost of automating batch processes.
central objectives are to:
• Reduce lifecycle engineering efforts.
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10 Commandments
for CIP Design
1. Always remember that water runs downhill…
By Maya Norris
Managing Editor, ProFood World
2. …and that it is easier to pump water into a tank
than to pump it out.
Clean-in-place (CIP) systems play an integral role in
sanitary plant design. They not only help food and beverage
manufacturers clean parts of equipment that are difficult
to reach, but CIP minimizes cleaning time and the labor
needed for it, ensures consistency and repeatability of the
cleaning process, improves efficient use of water and cleaning
chemicals, and ultimately increases the productivity of the
plant. Here are some tips from The OpX Leadership Network’s
CIP for CPGs: Clean-in-Place Guidelines for Consumer
Products Manufacturers that will help food and beverage
manufacturers design effective CIP systems.
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3. Pitch tank “CIP Return” manifold/connections continuously 9. Pitch all lines to easily opened drain points.
to pump inlet.
10. Design and install supports to eliminate “friendly” piping
4. Keep tank head nozzles few in number, short in length and that waves when starting pumps and opening and closing
large in diameter. valves because friendly systems are short-lived.
5. Avoid three-port divert valves like the plague. To download CIP for CPGs: Clean-in-Place Guidelines
for Consumer Products Manufacturers and CIP
6. Design to close all valves against flow. for CPGs: Clean-in-Place Checklist, visit www.
opxleadershipnetwork.org/hygienic-equipment-design/
7. Locate CIP systems in (near) and (when possible) beneath content/clean-place-guidelines-infographic.
the center of CIP loads.
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3. Skid construction. Ensure that the materials used 5. Modular design. The best way to design a skid is to lay out
in construction are acceptable for the intended plant the design in the beginning and determine the area required.
environment. Some facilities will not allow wooden skids, In the design phase, a layout can be made to determine the
for example, and the substitute for this must be approved best location fit. Although skid designs vary according to
well in advance. the engineer involved with the design of the equipment, the
best approach is to provide a modular layout so that in the
4. Similar to rafting. Skid mounting is similar to “rafting” of future changes can be made with the least amount of effort.
roll forming equipment. There are many elements of the roll Modular is the best layout because it makes it possible to
forming line, but the pre-process equipment incorporates the change the requirements.
coil handler and straightener and the post-process equipment,
including welder, cutter, deburrer and stacker, which are all 6. Base skid design on components. Create standard skids
easy to change over. The roll form can take hours; that piece based on the most important and standard components, such
is duplicated and indexed left or right. When left is forming, as number of membranes for RO units or other membrane
right is in changeover. Duplicating and indexing an element systems, or based on typical capacity of blowers and tanks.
of a line that requires extra attention could be interesting. Make sure to simulate the system to determine whether it
Indexing allows equipment to be swapped in a controlled will permit selection of a range of operation. Work in modules
manner, without the need for a forklift. located in parallel or series to increase capacity.
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Agreeing on OEE
“I don’t think we can say from our experience there is an
By Sean Riley industry standard. Too many variables at play within each
Senior Director, Media and Industry Communications, PMMI
line,” says Celie Reid, sales and marketing manager at Triple/S
Dynamics in Dallas. “The problem [with standard calculators]
As overall equipment effectiveness (OEE) insinuates itself into for us, as a conveyor manufacturer, is all of the bits and pieces
every sales opportunity, OEMs know that customers have a that make up the equation are totally out of our control.”
certain number in mind that represents their required OEE.
Defining OEE
The problem for OEMs is determining how their customers At a granular level, OEE can be calculated as the product of three
define that number. One company might perceive another percentages: availability, rate performance and quality. All losses
company’s accepted efficiency differently, since there are identified through the data collection process can and should be
many ways to calculate—downtime related to changeovers, attributed to one of these three categories to systematically drive
product in vs. product out, etc. There is also a variety of change at the appropriate level and magnitude.
calculators out there for determining OEE.
• Availability describes the losses that result from downtime,
From an OEM point of view, there is not yet an accepted both planned and unplanned. Some of the most common
industry standard for calculating OEE. types of availability losses result from maintenance and
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The OpX Leadership Network’s OEE Operational Reliability Robertson believes that most of the customers Pearson works
Solutions Group indicates 100 percent OEE is practically with understand what levels are achievable and what levels
impossible. Even if all three factors were 95 percent, OEE are pipe dreams. In the rare cases where customers require a
would calculate to just fewer than 86 percent. The worldwide higher-than-achievable level of performance, Pearson will do
average OEE rate in manufacturing plants is about 60 percent, everything it can to negotiate a workable compromise. If that
with 85 percent serving as the baseline from good to great. doesn’t happen, Pearson will decline the project rather than
risk disappointing a customer.
Leo Robertson, COO at Pearson Packaging in Spokane, Wash.,
agrees that 85 percent is considered a world-class figure. Being aware of your limits as an OEM is important when it comes
“The formula for that result would probably look like this: 90 to OEE, according to Bob Williams, vice president and general
percent availability x 95 percent performance x 99.9 percent manager at Raleigh, N.C.-based Axon, a division of ProMach.
quality= 85 percent world-class OEE,” he says. Of course,
actual expected performance and quality figures vary by “An OEM must know their equipment and accurately assess
model and application. “Based on the range of equipment the probability of success given the unique characteristics
[Pearson] manufactures, we can predict OEE figures to range of each application,” Williams says. “A customer who is not
from as low as 75 percent to as high as 89 percent. Availability realistic is dangerous. No one can afford a bad install, and
is primarily under the control of the end user and is usually the there are times when, given the conditions, it is better for
most variable metric.” an OEM to walk away than to take an order and then spend
thousands of man-hours and dollars trying to meet an
unrealistic performance guarantee.”
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That being said, he feels there is usually some level of It is at this point in the process that OEMs must push back
negotiation with OEE expectations, but timing is everything. against CPGs or avoid the project all together. Obviously, it
helps if you know your solution is the best or only one that will
“When pursuing the order, there seems to be no wiggle work for that particular application.
room and CPGs are looking for a number,” he says. “But after
the [purchase order] is placed, the expectations become “It really helps if the OEM has experience with the product,”
somewhat relaxed when other factors come into play like Reid says. “The main thing we do every time we receive
plant conditions, operators, environment, materials, etc.” an OEE requirement is to have several people read it very
carefully. Then we try to negotiate out things that we can’t
Reid has experience dealing with customers seeking the control, and keep our fingers crossed [that the CPG will be
impossible and responds with the caveat that what happens on realistic].”
the line before or after their machine is not included. She deems
this as the critical part of the equation for fellow OEMs. Several OEMs recommend reminding customers that
a machine builder cannot guarantee what an end user’s
“Most performance guarantees that we have been handed call employees will do once they receive the machine. The buyer’s
out ‘no less than 99.99 percent mechanical reliability, running undertrained employees can be a big problem, so those
for 15-20 eight-hour shifts,” Reid says. “This statement expectations need to be negotiated as part of the terms
is qualified by including the phrase ‘that an upstream or and conditions prior to purchase. Otherwise, it creates the
downstream event will not be included.’ Depending on where opportunity for disagreements further down the road. Some
your equipment is in the line, you can negotiate with a CPG.” OEMs ask that their customers’ employees have completed
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a training program as a condition of warranty. The high rate able to confidently commit to high performance and quality
of employee turnover creates opportunities for customers to figures. We also regularly break out availability factors such
change their expectations and not communicate it. as changeover time and machine breakdown issues to be
considered separately.”
While Pearson will walk away from
unrealistic expectations, Robertson
thinks those situations should be the
exception rather than the rule.
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Safety:
The Lifecycle Approach
For the process industries, IEC 61511 is probably the
By James R. Koelsch most widely used safety standard because it applies to
Contributing Writer, Automation World those industries that base their safety systems upon
instrumentation. The goal of safety-system design in IEC 61511
Dave Woll
is for the process, whatever it may be, to go to a safe state
Vice President, ARC Advisory Group
whenever a process parameter exceeds preset limits.
David Greenfield
Director of Content/Editor in Chief, Automation World A new way of approaching safety
Understanding IEC 61511 means that you must know a
thing or two about IEC 61508—a functional safety standard
Production safety is generally thought of as a series of that provides the framework for building industry-specific
steps necessary to ensure safe interaction with industrial functional standards. IEC 61511 was created from the
equipment. The process of identifying, agreeing upon guidelines established by IEC 61508.
and delineating those steps is where things tend to get
complicated. That’s why international standards groups play The key point to understand about IEC 61508 is that it is
such a significant role, as they set the guidelines for all of designed to establish an engineering discipline that will
industry to follow. generate safer designs and build safer processes. The uniform
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In essence, the standards specify safety lifecycle activities Specific activities include:
that need to be followed over the entire life of a production
system. Safety lifecycle management provides a method • Perform hazard and risk analysis: Determine hazards and
or procedure that enables companies to specify, design, hazardous events, the sequence of events leading to hazardous
implement and maintain safety systems to achieve overall conditions, the associated process risks, the requirements of
safety in a documented and verified manner. risk reduction and the safety functions required.
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• Allocate safety functions to protection layers: Check the • Design and develop other means of risk reduction: Means
available layers of protection. Allocate safety functions to of protection other than programmable safety systems
protection layers and safety systems. include mechanical systems, process control systems and
manual systems.
• Specify requirements for safety systems: If tolerable risk
is still out of limit, then specify the requirements for each • Install, commission and validate the safety protections:
safety system and its safety integrity levels. Install and validate that the safety system meets all the
safety requirements to the required safety integrity levels.
Safety Lifecycle II: Realization phase
The realization phase not only includes design, installation and Safety Lifecycle III: Maintenance phase
testing of safety systems, but also the design, development The maintenance phase begins at the startup of a process
and installation of other effective risk reduction methods. and continues until the safety system is decommissioned or
Specific activities include: redeployed. Specific activities include:
• Design and engineer a safety system: Design the system to • Operate and maintain: Ensure that the safety system
meet the safety requirements. functions are maintained during operation and maintenance.
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• Manage
functional safety, safety assessment and safety audit: Identify
the management activities that are required to ensure that the functional
safety objectives are met.
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Conducting
a Risk Assessment
stop the machine for changeovers, to clear jams, or to clean or
By Jim Chrzan perform routine maintenance.
VP, Content and Brand Strategy, PMMI Media Group
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• Vendors
• System integrators
• Field technicians
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• Reporting or regulatory entities • The attacker can use captured or guessed credentials to
impersonate the user.
• Managed service providers
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• The attacker can intimidate or coerce the user to provide (does not rely on impersonation) or intercepted during
valid credentials, or to perform activities at the attacker’s initiation (impersonating both user and target, also known as
demand. a man-in-the-middle attack).
• The user’s access device (laptop, PDA, etc.) can be • Parts of a communication can be replayed to a target, even
attacked, compromised, and used to access the control if the attacker cannot decipher the content (also known as a
system network. replay attack).
• The target system can be impersonated by an attacker to • The target communication software listening for requests
fool the user and thus gain credentials or other information can be attacked and potentially compromised.
from the user system.
• An attacker can impersonate a valid communications node
• Communication can be listened to by third parties anywhere and gain access to the underlying communications medium.
along the communication chain.
• A denial-of-service attack can happen to the authentication
• The communication can be interrupted or jammed. server (e.g., radius server or RAS).
• Communications can have data injected into them by an attacker. • A denial-of-service attack can happen to the outward
communication device (e.g., an outside router for remote
• Communication can be hijacked after it has been initiated access).
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Convened by PMMI, The Association for Packaging and Processing “While the technologies enabling remote equipment access
Technologies, the OpX Leadership Network’s new Remote have been present for some time, adoption has been slow,”
Equipment Access: Options Analysis tool provides a common says Christopher Hough, general manager of ZPI, a ProMach
understanding of the industry methodologies for remotely Product Brand. “The OpX Leadership Network’s new solution
accessing equipment installed in manufacturing facilities. can help bridge the gap and provide guidance on remote
equipment access options.”
Based on the collective experience of the OpX Leadership
Network’s Remote Equipment Access Solutions Group, this The OpX Leadership Network was founded in 2011 by PMMI
discussion tool was created for production teams to consider to ensure CPGs and OEMs are well-connected and well-
approaches for enabling access to equipment for diagnosis, prepared to solve common operational challenges, make
potential repair and performance improvements from remote smarter decisions and achieve operational excellence.
suppliers that are not part of the customer’s company.
Remote Equipment Access: Options Analysis, as well as other
Consumer packaged goods (CPG) companies as well as operational solutions, are available for free download at
their suppliers, OEMs and service providers can benefit www.opxleadershipnetwork.org.
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4 IT Standards You
Should Understand
• The ANSI/ISA 88 standard on batch control.
By Dennis Brandl
Chief Consultant, BR&L Consulting Inc. • The ANSI/ISA 95 standard for MES and ERP-to-MES
communication.
Imagine a world without electrical standards, such as 110 V • The ANSI/ISA 99 technical reports in industrial cyber
at 60 Hz, or 220 V at 50 Hz, or a world where every phone security.
had a different type of connection and required a different
type of switchboard. Just as these standards are critical to • The new ANSI/ISA 106 technical report on procedure
the basic functioning of electrical equipment, there are also automation.
IT standards used daily to ensure optimal functioning of
production systems in the process industries. These standards and technical reports define the best
practices for implementing automated and manual control
There are four production-related IT standards of special on the systems that reside above the programmable logic
interest to the processing industries: controller (PLC) and distributed control system (DCS) level,
and which perform the basic control that keeps production
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running. These four standards all share a common view of a The ANSI/ISA 99 reports define structures and policies for
production facility, providing a consistent terminology that designing effective and secure networked production facilities.
makes it easier to compare plants within a company and
across companies. The new ISA 106 reports define the procedural control
strategy for continuous production during upsets,
The ANSI/ISA 88 standard defines the most common and switchovers, and other types of process changes.
effective method for defining control systems for batch
operations or for continuous and discrete startups and Because these standards establish a commonly accepted
shutdowns. terminology, functions and process models by which
technical professionals are trained, and upon which solution
The ANSI/ISA 95 standard defines the most commonly used providers develop applications used in batch and process
method for exchanging information between enterprise production operations (as well as discrete manufacturing),
resrouce planning (ERP) systems, such as SAP or Oracle, they should be of particular interest to those who are new to
and the multitude of shop floor systems. It has also become the field and those seeking a refresher on the fundamentals
the de facto standard for defining manufacturing execution of industrial processes.
system (MES) and manufacturing operations management
(MOM) specifications.
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CONTINUED Tips for Dealing With Wireless Latency and Bandwidth Issues
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CONTINUOUS
PROCESSING
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The following experts
SECTION 3 Continuous Processing CONTRIBUTORS
contributed to this playbook:
Brooke Robertson John Rezabek
Project Manager Regional Control Specialist, EPCD Process Control Specialist
Momentive Specialty Chemicals Inc. Ashland Specialty Ingredients
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The following experts
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contributed to this playbook:
Cyle Nelson Steven Baird Dave Emerson
Senior Software Architect Moxa ISA-106 Editor
Adept Technology Yokogawa
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The following experts
SECTION 3 Continuous Processing CONTRIBUTORS
contributed to this playbook:
Randy Durick Vignesh Kumar Dale Reed
Turck ISA-106 Editor Rockwell Automation
Yokogawa
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The following experts
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contributed to this playbook:
Sarah Wang
Fluor
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The following experts
SECTION 3 Continuous Processing CONTRIBUTORS
contributed to this playbook:
Control System Integrators Chetan Chothani Bryan Curtis, P.E.
Association (CSIA) President Senior Consultant, Power/
Automation World worked with Adaptive Resources Facilities Dept., Matrix
CSIA to gain access to the expertise Technologies
of its system integrator members
to bring you much of the content in
this playbook. Alan E. Lyon, P.E. Antonio Manalo
Lead Engineer Automation Systems Integrator
To become a member of CSIA, a
control system integration firm Avid Solutions Avid Solutions
must demonstrate experience and
commitment to the field. Members
who earn CSIA Certification have
passed an independent audit of Alex Palmer Dario Rossi
80 criteria covering all aspects of Team Lead Chief Engineer
business performance, including Aseco Integrated Systems Aseco Integrated Systems
general management, financial
management, project management,
quality management, supporting
systems, human resources and more. Scott Saneholtz, P.E. Robert Snow
To maintain their certification, CSIA Manager Senior Process Control
Certified members must be re- Process Solutions Dept. Engineer Optimation
audited every three years.
Matrix Technologies
For more information about CSIA
and its system integrator members,
Ronald Studtmann, P.E. Russel Treat
visit http://www.controlsys.org.
Associate Dept. Manager, Power/ President-CEO
Facilities Dept., Matrix Technologies EnerSys Corp
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that it depends on the needs of your application. Here are six geographic area with thousands of I/O points, a DCS makes
key factors to consider: more sense.
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change often. If your process is complex and requires and a generation of experienced process control personnel
frequent adjustments or must aggregate and analyze a large has begun to retire. As a result, the quality of support has
amount of data, a DCS is typically the better solution. Of become a critical factor in vendor selection.
course, the very flexibility of a DCS system also makes it
much more vulnerable to “meddling” by operators that can
cause spurious shutdowns.
6. Vendor support
DCS vendors typically require users to employ them to
provide integration services and implement process changes.
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The thinking behind both of these standards has important ISA-106 defines continuous process procedures
implications in areas where continuous process control is most A new ISA committee is working to develop standard
vulnerable—process variations and disruptions. These can methods and terminology for automating continuous process
result in unanticipated shutdowns that plant operators can be procedures. “ISA-106, Procedural Automation for Continuous
ill equipped to counter because they’re not confronted with Process Operations”, will define repeatable procedural steps
them frequently enough to hone their skills. that can lower the chances of accidents due to human error.
The intent of the new standard is to reduce process variability,
Automating procedural steps can counteract variations in reduce risk to facilities and increase operational productivity
operator skills and will become increasingly important as the in continuous process industries.
current generation of experienced process control engineers
retires. Defining common process procedures can also The ISA-106 committee plans to issue a series of documents
provide additional support for employees who are executing to help users standardize designs to handle operator errors in
operations that can be more manual, as is typical in equipment normal, critical, and abnormal situations.
and plant startups, shutdowns and transitions.
As a first step, the ISA-106 committee, which includes
representatives from the largest companies in the
petrochemical industry, is working on its first technical
report targeted at oil refineries, upstream offshore oil
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THAT PUT YOU IN CONTROL
SECTION 3 Continuous Processing
From single control room consoles to the largest integrated
Accessible Cable
Management
Solutions
Multiple Work
The technical report will also include standards Surface Options
and Styles End Panel Color,
Material and
for modularizing procedural steps, exception Graphics Options
Dozens
handling for abnormal situations, state mode of Accessories,
Hundreds of PC/Device/Instrument
Multiple Depths
and Conngurations
Conngurations, Security with Swing-Out
procedural logic, process unit orientation and Unlimited Possibilities Authorized Accessibility Standard Modular, Modiied or
Full Custom Console Solutions
current practices.
FREE 3D DESIGN
SOFTWARE & DESIGN SERVICES
Download our free WELS 3D software that lets you
design, visualize and cost your ideal control room
solution. Or contact us for free design services.
GET IT AT: WINSTED.COM/WELS
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has many benefits in terms of technology, investment, 5. Consider three critical migration issues. When doing a
maintenance and lifecycle cost. migration there are three points to think about: how to update
software and whether you have the right conversion tools; what
3. Take it one step at a time. Avoid changing the entire system you need to do to avoid system failure or risk for the migration
or manufacturer if you are upgrading. Upgrading to the newer step; what is the expected lifecycle of the new system.
modules or systems of the same vendor provides a bit more
reliability, since the basic architecture remains the same. 6. Make no assumptions. Try to foresee every small step in
a migration implementation. Don’t assume anything. Every
4. Don’t experiment. While innovation is important, there implementation is done to achieve some objective of the
is a counter-argument for doing what you know will work. operation. The needs could range from some reporting or alarm
If rip-and-replace is possible (and that means you have to functions to an action initiated due to alarm. Always visit the site
stop the plant for several days, weeks, or months depending to understand the requirements and the nuances completely.
on the circumstances) and you know that it works, that is
the best choice. But if you can’t afford a shutdown, then go 7. Changing suppliers adds some complexity. The difficulty
for a step-by-step migration. Make sure you work with an of a process migration usually increases when you change
experienced vendor and proven technology. DCS suppliers, since different brands often don’t have similar
functions. Factor that into your timeline and risk assessment
when weighing whether to switch vendors.
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8. Start with data needs. First you need to understand what 11. Technology education. It is important to educate everyone
data the user will require and how quickly the data is needed. on the new technology. Remember, it is easy to use “old”
That should be the starting point in developing your migration thinking instead of changing practices to take advantage of
strategy. The second priority is to determine the impact on the benefits of the new technology.
the safety and productivity of the plant.
12. Decentralize. The architecture has to be critically reviewed
9. Focus on controllers. The best strategy is to first upgrade and transformed, keeping in view the improved performance
the controllers, then replace the I/O chassis piece-by-piece of the local controllers. Your mantra should be to decentralize
going forward. Some I/O changes could be driven by other the controls as far as possible.
projects, such as a motor control center(MCC) replacement.
13. Aging equipment. Depending on the technology you
10. Do your homework. Do some upfront analysis to avoid have installed, when your equipment is more than 10 years
creating problems for yourself by not choosing the right old you will need to implement a rip-and-replace. If you are
migration path. For example, migrating from one generation just making some modifications you can upgrade or make
of processor to another one may not be a wise choice. an expansion only. Most of the problems that arise during a
Reviewing the instruction sets and information available about migration are with the field equipment you have installed and
conversions and manufacturer recommendations will give you control room facilities.
insight into the difficulty of the conversion. If you do your
homework, you might choose a different processor to make
the conversion easier.
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THAT PUT YOU IN CONTROL
SECTION 3 Continuous Processing
From single control room consoles to the largest integrated
command centers, only Winsted has more exible solutions
CONTINUED Managing for Reliability Key for you to meet your exact requirements for function, style and
cost. Select the conn guration, design and features you want in
to Asset Performance modular, modii ed or full custom console environments.
mistake and results in frustrated engineers who take longer Accessible Cable
Management
Solutions
to solve a problem and are unsure of the best practices to Multiple Work
Surface Options
and Styles End Panel Color,
use to make sure the problem does not come back. Material and
Graphics Options
Dozens
of Accessories, Multiple Depths
Hundreds of PC/Device/Instrument and Conngurations
Proactive-minded users, on the other hand, have seen the Conngurations,
Unlimited Possibilities
Security with Swing-Out
Authorized Accessibility Standard Modular, Modiied or
Full Custom Console Solutions
benefits of this service philosophy. They see training and
certification as an investment to ensure not only that results
don’t erode, but that production and quality performance
continue to improve.
FREE 3D DESIGN
SOFTWARE & DESIGN SERVICES
Download our free WELS 3D software that lets you
design, visualize and cost your ideal control room
solution. Or contact us for free design services.
GET IT AT: WINSTED.COM/WELS
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Additional simple measures, such as the percentage of control The next step is to measure and monitor control performance
valves at a limit, and overall variability, can give you a better regularly. Software tools can monitor various measures,
idea of the opportunity for savings at your plant. Start by provide reporting and notification of problems. This step is
taking a random sample of 100 control loops. In one hour critical to recognizing where problems exist in your plant on
sitting with the operator, you can confirm whether your plant any given day.
has a significant opportunity to improve.
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Automated monitoring also allows for more sophisticated various parts of the process, need more sophisticated analysis.
measures and diagnostics. Modern software tools can find Tools such as Fourier Transforms and the resulting power
failed instruments, broken control valves, poorly tuned spectrum chart, shown in Figure 3, can find the cause of
controllers and process problems. These analytics are needed oscillation problems.
for the next step: resolving the root cause of the problem.
Process Interaction analysis, as shown in Figure 4, can also be
If 30 percent of controllers are operating in manual mode, the used to pinpoint the cause of a problem that may be far
solution is not as simple as putting everything into automatic upstream in the plant.
mode. Chances are, the operator put these controllers in
manual for a reason. Any good control performance project With the problems identified and prioritized, your focus can
can use data from your process historian to help pinpoint and now turn to managing the required repairs, tuning changes
resolve the true root cause of the issue. and process adjustments. This work should be managed and
organized like any project: with specific plans, assignment of
Some problems, such as valve stiction, have a unique signature responsibilities and expected completion dates. Some repairs
pattern, as shown in Figure 1. The square wave pattern on the may need to wait until planned shutdowns, but others can be
process measurement and sawtooth movement of the control completed on the fly.
output are a sure sign of valve stiction. The ladder pattern in the
PV/CO plot shown in Figure 2 further confirms valve stiction. Finally, it is important to track the effect of these
improvements. A simple before/after trend can be very
Other problems, such as oscillations and interactions between useful to show the results. Whenever possible, you should
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If you have enough staff at your plant, each of these steps can
be accomplished in-house. Experienced software and service
suppliers can also provide all or part of these activities as a
service, starting with site evaluation and progressing all the
way through capture of benefits and sustaining the results.
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10 Steps to Creating
the Perfect HMI
When developing HMI screens, realize that you are the display according to the amount of information that
attempting to capture the essence of the machine or process, is most important for the operator to see. Always discuss
not just posting key automation variables and control requirements with the equipment’s operators well ahead of
mechanisms. Operational feedback is vital for efficient HMI time, not just with their managers. Operators usually have
screen layouts. Think of yourself as an artist, commissioned by different needs and the success of your system depends on
manufacturing operations to create the HMI screens. their usage.
1. Less is more. It’s important to keep the HMI simple and with 3. Design tips. A good design requires careful use of layout,
the operator in mind. It’s best when it’s self-explanatory and color and content. If you get it wrong, your operator misses
easily understood. Also, try to make the pages similar and an indication, you lose money, or worse, someone is injured.
follow the same page layout throughout. Avoid making the The “bad” screen is less than satisfactory: The layout is poor,
display too technical. It’s normal for engineers to try to give the plant representation isn’t logical and the screen layout
the customer everything, but with HMI, less really is more. makes it difficult to locate the data. Poor selection of colors,
excessive use of capitals in a serif font and repetitive use of
2. Right-size displays. Don’t try to save money by selecting units with all data values makes this a really difficult screen to
an HMI display screen that’s too small. It’s also important read—especially at a glance or from a distance. Avoid colors
not to cram too much information onto a screen. Size that could create problems for people with color blindness.
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5. Location, location, location. Real estate can be prime in information from the process database for the historian. This
a busy production area. Locate the HMI in a practical place, will reduce the load on the system and keep it from stalling or
out of heavy traffic areas but accessible. Be aware of near- failing. Don’t forget the need for maintenance and make sure
future projects in the area. Guard the HMI location so others you schedule periodic backups.
don’t park or configure something else on top of the station.
9. Think about flow. It is essential to have a clear design
6. Back up work periodically. Backups are especially important approach to the HMI. Decide how the display blocks naturally
before implementing upgrades or changes. Software such flow and how sections need to be grouped together for
as Norton’s Ghost Image can be invaluable to support and the operator. Do not blindly follow P&I diagrams. The S88
maintain HMI systems. functional hierarchy is a good place to start. Make paper-
based designs to get a feel for screens, navigation and other
7. Visualize the process. HMI graphics should illustrate the requirements, and review with clients prior to designing and
production process in the plant to provide better visualization making electronic screens.
to the operators, giving them a sense of the action that’s
required. Use hardware that meets minimum requirements 10. Alarm strategy. Alarming needs to have a well-
and keeps the number of failure points low and assures high articulated strategy. Alarms must be used for conditions
availability of the system. that require intervention and must have a clear corrective
action associated with each one. Anything else should not
8. Only essential data. Make control and monitoring of be an alarm.
the process simpler by selecting only the most essential
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3. Do it right. Using the right barriers and the proper certified 5. Limit risk. Don’t operate equipment in hazardous areas
devices at both the field and the systems end should solve needing intrinsic safety systems. As for operator safety, keep
the problem. The standards clarify the requirements and it is control signal voltages below 24 VDC. No human-operated
absolutely essential that the standards be followed with zero selector or push button should have voltages over 24 VDC. It
exceptions. It also makes sense to seal conduits to eliminate simplifies servicing and monitoring.
the migration of hazardous gases. With all systems, proper
grounding is very important. No compromise should be 6. Protect controllers. If you are installing intrinsically
tolerated when it comes to safety. safe systems, it’s very important to protect all automation
controllers and module cards. Intrinsic barriers for fieldbus,
4. Test everything. The most important thing when Modbus and conventional I/O card loops is a best practice.
implementing an intrinsic safety system is to test it. Make
sure that what has been done is correct so you can sleep 7. Troubleshooting issues. Intrinsic safety brings along some
well at night. Test the design and the system, make it pass all troubleshooting issues. Any time you decrease your current
the assessments and put it as a requirement for the project. you allow the possibility that smaller voltage drops will give
It will be first page news if something goes wrong, so make you bigger issues. Inputs and outputs are easily affected by
sure to supervise the installation very closely, and be sure loose connections on intrinsic safety circuits. Make sure all
that the design is not changed at the execution. connections are tight and practice good wiring practices to
minimize this issue.
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8. Less maintenance. An intrinsically safe solution is 10. Hardware intensive. Security people may think all the
recommended over explosion-proof technology if only areas need to be explosion proof. It really depends on the
a limited number of instrument loops are involved. After experience with your equipment or plant. Look at incident
implementation, this technology does not require any special statistics and the problems you see to determine where
maintenance attention compared to the traditional North you need intrinsic safety and where not. Implementation
American approach. There are even DCS I/O modules that of intrinsic safety is often very hardware intensive, so many
are IS-certified and do not require a separate IS barrier. By plants try to avoid it. Many PLCs and hardware out there are
refurbishing with low power equipment, you can reduce the Class 1 Div. 2 compliant. A separate IS implementation may
surveillance rounds and maintenance checks. not be essential.
9. Voltage drops. Do not neglect the voltage drop due to 11. Alternative approaches. Early in a safety project, develop a
resistance of field wiring when designing 4-20 mA loops. comprehensive P&ID followed with a hazop review to assess
During commissioning, it is common to find loops that risk and identify safety issues. This will allow you to investigate
functioned properly at low currents but stopped operating alternative ways to minimize risk, such as process modifications
entirely as the current approached 20 mA. This is because or changes in the type of process equipment. The intent is to
enough voltage dropped across the field wiring to reduce minimize the need to implement an SIS system or to minimize
voltage across transmitters to less than the compliant SIS loops. Focus safety efforts on protecting the areas of the
voltages they needed to operate. process most critical to the continuity of production.
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• A
major pharmaceutical manufacturer recently
decided to instrument all of its R&D equipment,
such as incubators and cryofreezers, and connect
them to the company’s control systems for 24/7/365
monitoring. Because much of this equipment has
casters, it was difficult to wire them, as they need to
be moved around. This project is still ongoing, but
there are currently nearly 2,000 pieces of equipment
equipped with wireless sensors on the company’s
R&D campus, which covers an area of about 1.5 km.
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Managing Emissions
With Automation
industrial facilities, including trash burners and industrial
By Jeanne Schweder boilers, even if they only generate process steam. More
Contributing Writer, Automation World
stringent controls on particulates will also require new
investments in emissions technologies.
Industries where emissions control is critical include electric
utilities, oil and gas, chemical processing, iron and steel, NOx and SOx reduction
paper, food, mining, metals and cement. But emission control The U.S. Clean Air Act, the Clean Water Act, the pending
concerns are not limited to these industries. Systems to Casper regulations and proposed Environmental Protection
control and reduce emissions are required for any industrial Agency (EPA) limits on greenhouse gases are driving the
process that produces sulphur and nitrogen dioxides development of improved emissions control technologies.
(popularly referred to as SOx and NOx), the major causes of Casper regulations will further reduce NOx and SOx emissions
acid rain, as well as airborne particulates and volatile organic limits in the Northeast and in certain states such as Texas
compounds (VOCs). and Illinois. In addition to these government measures, green
initiatives by corporations also emphasize emission reductions.
On the horizon are new regulations designed to limit
mercury emissions in flue gas. These rules will also apply to The list that follows touches upon the primary emission
reduction methods used in industry:
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• At the stack, the air from the process is passed over a rack
of sensors that measure oxygen, carbon dioxide and carbon
monoxide levels, as well as sulphur dioxide, sulphur trioxide
and nitrogen oxide content.
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VENDOR SELECTION RESOURCE GUIDE Winsted
Winsted is a worldwide leader in control room console solutions. combine the disciplines of industrial design,
We create attractive, ergonomic consoles that work with your ergonomics and interior design to create
operators to improve comfort and optimize efficiency. We offer solutions that are both efficient and eye-catching. We give special
stock, customized and custom consoles suitable for any control consideration to the ergonomic requirements of your operators to
room application. Whether you are building a state-of-the-art build consoles that reduce fatigue, improve productivity and inspire.
control room from the ground up, or simply need to upgrade your Our commitment to customer service is second-to-none and your
operations, Winsted can provide the ideal solution. Our experts satisfaction is guaranteed.
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VENDOR SELECTION RESOURCE GUIDE Winsted
in England. Since then, Winsted, Ltd. has become a successful In 2002, Winsted acquired Technical Interiors,
marketing and manufacturing operation serving the European, a Georgia-based company with 25 years of
Middle Eastern and African markets. In 1986, distributor experience designing and manufacturing custom consoles of the
agreements were established in Australia, Japan, Hong Kong, highest standards for the nuclear power industry. Technical Interiors
Taiwan and Korea. was renamed Winsted Custom Division in 2010 and solidifies our
mission of providing the highest quality console and furniture
solutions to mission critical facilities around the world.
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VENDOR SELECTION RESOURCE GUIDE Winsted
WEB RESOURCES
WHITE PAPER:
Human Factors: Planning & Designing a Control Room
http://winsted.com/img/resources_literature/human_factors.pdf
ONLINE CATALOG:
http://catalog2012.winsted.com/t1.asp
YOUTUBE CHANNEL:
http://www.youtube.com/user/winstedcorp
PRODUCTS:
http://winsted.com/products.htm
COMPANY CONTACT
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VENDOR SELECTION RESOURCE GUIDE Banner Engineering
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costs. In addition, IO-Link sensors help reduce unplanned systems easier and more visual. From easy-align light curtains
downtime thanks to remote configuration and monitoring, to drag-and-drop safety controller software, safety solutions
advanced diagnostics, and auto-device replacement. from Banner can be commissioned quickly and help you
comply with safety regulations while maintaining productivity.
Intuitive Safety – Banner combines easy-to-use safety devices
with LED indicators to make managing complex safety Quality Without Compromise – Improve quality control and
productivity with flexible solutions that meet your application
requirements. Banner’s broad range of solutions includes
sensors and vision for automated error-proofing; bright, even
illumination for visual inspections; and LED indicators that
ensure operator and assembler accuracy.
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VENDOR SELECTION RESOURCE GUIDE Banner Engineering
WEB RESOURCES
WHITE PAPER
What IIoT Means for Manufacturing
awgo.to/854
VIDEO
Vibration Monitoring for Predictive Maintenance
awgo.to/855
ARTICLE
The 5 Advantages of IO-Link
awgo.to/856
COMPANY CONTACT
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VENDOR SELECTION RESOURCE GUIDE Visual Components
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VENDOR SELECTION RESOURCE GUIDE Visual Components
Visual Components provides a platform to virtually test and of simulation experts, we started with a humble goal – to make
validate the design of your production solutions. Simulating the manufacturing design and simulation technology easy to use and
workflow yields production statistics and insights, such as cycle accessible to manufacturing organizations of all sizes.
times, production rates, and process bottlenecks; giving valuable
information that can be used to evaluate how changes in layout Today, Visual Components is recognized as a global leader in
design, resource planning, and variability affect production. the manufacturing simulation industry and trusted technology
partner to many leading brands. We offer machine builders, system
Visualize complex production data and turn it into proposal- integrators, and manufacturers a simple, quick, and cost-effective
ready content. Visual Components empowers manufacturing solution to design and simulate production solutions. With solutions
professionals to create marketing-grade content with engineering- for manufacturing
grade accuracy, so you can highlight the capabilities of your design, sales,
production solutions and sell your vision. and application
development,
Easily export presentation-ready content for your proposal – such Visual Components
as 2D drawings, interactive 3D PDFs, 4K videos and high-resolution software is trusted
images – directly from the software. And, with the new Visual by hundreds of
Components Experience, you can export your simulations to run on organizations
our mobile and virtual reality applications. worldwide to support
critical planning and
About Visual Components decision-making
Visual Components is a leading developer of 3D manufacturing processes.
simulation software and solutions. Founded in 1999 by a team
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VENDOR SELECTION RESOURCE GUIDE Visual Components
WEB RESOURCES
VIDEO
Design, Optimize, and Visualize the Factories of the Future
www.youtube.com/watch?v=cjxOX3JQWcs
CASE STUDY
IAS – Bringing the Future of Automation into View
www.visualcomponents.com/insights/case-studies/ias-case-study-future-automation/
PRODUCT
The Visual Components Product Family
www.visualcomponents.com/products/visual-components-4-0/
COMPANY CONTACT
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VENDOR SELECTION RESOURCE GUIDE nVent HOFFMAN
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VENDOR SELECTION RESOURCE GUIDE nVent HOFFMAN
Connect your application with our solutions. Paired with our automation equipment performance and increases safety of people,
thermal management solutions comes monitoring software products and performance.
in Remote Access Control (RAC). RAC provides visibility to
cooling devices across multiple global locations from a single When it comes to your equipment and employees,
network. RAC provides immediate detection of temperature nVent HOFFMAN connects and protects.
fluctuations as well as remote control of temperature settings
for individual or groups of cooling system units. Thus, lowering
maintenance costs with increased energy efficiency and
reduced instances of failure or need for replacement.
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VENDOR SELECTION RESOURCE GUIDE nVent HOFFMAN
WEB RESOURCES
NVENT WEBSITE
Learn more about nVent and its brands
https://www.nvent.com
VIDEO
Who is nVent?
https://youtu.be/e6zfPQzQubY
VIDEO
Choosing an Electrical Enclosure Cooling Solution
https://youtu.be/uoYUGUChnvk
COMPANY CONTACT
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VENDOR SELECTION RESOURCE GUIDE IDEC
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2,060 digital I/O and/or 511 analog I/O. It is also one of the first MOVING INTO THE FUTURE
micro PLCs to offer full-featured app access from any iOS or As a member of the UN Global Compact, a movement of sustainable
Android smartphone or tablet. Trying to reduce costs and enhance companies, our mission is to continue developing smarter products,
performance? Combining PLC processing and HMI monitoring in advancing the IIoT and creating a sustainable planet.
one unit, the FT1A Touch HMI+PLC makes it faster and easier to build
compact smart machines, reducing initial design and maintenance
costs by eliminating extra components and duplicate programming.
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VENDOR SELECTION RESOURCE GUIDE IDEC
WEB RESOURCES
IDEC WEBSITE
Learn More about IDEC and its brands
http://www.idec.com/usa
VIDEO
https://www.youtube.com/user/IDECUSA
COMPANY CONTACT
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