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A recipe
for success
Finding the right mix for
a salad dressing line 50
PlantEngineering.com
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KAESER SUCCESS STORY
COMPRESSORS
PROBLEM:
At a plant manufacturing turbines for hydro-electric power plants,
excess capacity had been a source of comfort for many years despite
recommendations for system updates. Four modulating, twenty-year
old compressors, two 75 hp, two 25 hp, supplied the systemwithout
central controlscausing excessively high energy costs. When a new
plant engineer came on board, he took a closer look at the energy
efficiency. Having attended a Kaeser Compressed Air Seminar, he knew
a systems approach could unlock significant savings.
SOLUTION:
Kaeser ran a KESS (Kaeser Energy Saving Simulation) using supply
side audit data and designed a complete system solution that would
dramatically reduce the specific power from 62.0 kW/100 cfm to 17.5
kW/100 cfm. New energy efficient compressors, an air receiver, as well
as a system master controller were installed. The new system has the
same number of compressors and total horsepower as before, but it
kaeser.com
RESULT:
The Sigma Air Manager (SAM) master controller monitors the four new
compressors and selects the most efficient combination of units to meet the
plant demand. With its built-in SAC Plus software, SAM continually tracks
energy consumption so the plant benefits from having an ongoing com-
pressed air energy audit. As a matter of fact, the specific power has been
reduced more than anticipatedall the way down to 16.7 kW/100 cfm.
Let us help you measure and manage your compressed air costs!
input #2 at www.plantengineering.com/information
PUTS YOUR
and product options can help you design
the best risk mitigation solution, as well
as support your compliance efforts and
MOST VALUABLE performance needs. Customers have relied
ASSETS
on our high-quality dust collectors in over
250,000 installations. Now, more companies
look to us to integrate their dust control
AT RISK.
systems with re and explosion protection
equipment and strategies. Your Donaldson
Torit representative can listen to your needs,
work with you to identify options and
implement a customized dust management
solution unique to your plants requirements.
DonaldsonTorit.com
800.365.1331 LEARN MORE
Go with Donaldson Torit and get Visit donaldsontorit.com/
EXACTLY WHAT YOU NEED. combustibledust
2016 Donaldson Company, Inc.
input #3 at www.plantengineering.com/information
January/February 2016
Volume 70, No.1
201 5
Salary Survey
Despite the relative strength of the U.S. manufacturing market, the monthly PMI Index put out by the
Institute for Supply Management declined for seven straight months and fell into contraction for the first
time in three years in November.
These are nervous days.
Thats why it is not surprising that for the first time in a decade, the primary concern of plant managers is
the economy, according to the 2015 Plant Engineering Salary Survey. In past years, the top issue was the lack
of a skilled workforce, and that checks in as managers second-largest issue, but the economy was clearly a
bigger concern at the end of 2015.
Analyst Insights:
38 Who We Are 44 Andy Chatha, ARC Advisory Group
40 What We Earn 46 Michelle Drew Rodriguez, Deloitte
42 What We Think 48 Bob Parker, IDC
49 Alex West, IHS
PLANT ENGINEERING (ISSN 0032-082X, Vol. 70, No. 1, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.
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WELDING
SHOT PEENING
AND MORE
Scan QR Code,
Place Phone Here
Turn your phone into a
window to actually see inside
the Farr Gold Series.
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LOOKS LIKE A SAFE BECAUSE ITS
TM
866-354-8794 www.camfilapc.com
PlantEngineering.com
50
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TRUDY KELLY, Executive Assistant
630-571-4070 x2205, TKelly@CFEMedia.com 50 A recipe for long-term growth
ELENA MOELLER-YOUNGER, Marketing Manager Pinnacle Foods invested a reported $50 million in its plant in St. Elmo, Ill., when it
773-815-3795, EMYounger@CFEMedia.com
acquired the Wish-Bone salad dressing brand, but the plants investment in equip-
KRISTEN NIMMO, Marketing Manager
630-571-4070 x2215, KNimmo@CFEMedia.com ment, people, and training has allowed the plant to find quick success in less than a
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KATIE SPAIN, Art Director
630-571-4070 x2218, KSpain@CFEMedia.com Electrical Solutions
PAUL BROUCH, Director of Operations
630-571-4070 x2208, PBrouch@CFEMedia.com 55 Protecting the smarts in electrical smart metering
MICHAEL ROTZ, Print Production Manager
717-766-0211, Fax: 717-506-7238
As the complexity of smart meters increases, so does their vulnerability to circuit
mike.rotz@frycomm.com threats. To ensure these meters continue to work, even in hostile operating condi-
MARIA BARTELL, Account Director, Infogroup Targeting Solutions tions, robust circuit-protection technologies are essential.
847-378-2275, maria.bartell@infogroup.com
RICK ELLIS, Audience Management Director
303-246-1250, REllis@CFEMedia.com Mechanical Solutions
LETTERS TO THE EDITOR
Please e-mail your opinions to BVavra@CFEMedia.com 61 The value of VSDs in improving efficiency
INFORMATION
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For custom reprints or electronic usage, contact:
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INTERACTIVE www.plantengineering.com
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CONVEY DUMP UNLOAD
FLEXI-DISC Tubular Cable
FLEXICON Manual
BULK-OUT Bulk
Conveyors gently slide fragile Dumping Stations allow Bag Dischargers
foods and non-foods through dust-free dumping of bulk unload free- and
smooth stainless steel tubing material from bags and other non-free-flowing
routed horizontally, vertically containers. Automatic reverse- solids from bulk
or at any angle, over short pulse filter cleaning allows bags automatically.
or long distances, dust-free. continuous, efficient Allows untying,
Single or multiple operation. Available discharging, retying
inlets and with integral bag and collapsing of
outlets. compactors for bulk bagsall
total dust dust-free. Available
containment. with weigh
batching controls.
2015 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
*See full Lifetime Performance Guarantee for details.
input #6 at www.plantengineering.com/information
IN FOCUS
The Industrie 4.0 platform is a part of the Internet of Things world, including more embedded and collaborative intelligence
such as smart factories, smart services, smart devices, and smart products, which all bring about benefits in the new era of
connectivity. Image courtesy: Schneider Electric
The benefits of the Industrial Internet IIoT offers both new challenges storage and analytics are combined
of Things (IIoT) are becoming more and opportunities for manufacturers with machine-to-machine commu-
apparent as industry experts debate willing to push the boundaries of nication, smart machines are able to
the opportunities at hand. Ushering a machine and plant design. Included in consistently capture and communi-
new era of connectivity, where plants these new opportunities are benefits cate data better and more efficiently.
and machines work together in a secure such as connectivity, efficiency, and Analyzing historical data allows
and collaborative way to enable tech- reliability, but many features of IIoT manufacturers to identify inefficien-
nology at the service of people, IIoT technology may bring great financial cies in production and other areas
is providing greater empowerment benefits to manufacturers as well. of improvement for reducing time to
and efficiency. While the potential for market. It also allows them to bet-
data and efficiency gets most of the Increasing profitability with IIoT ter manage operating expenditure
attention, the smartest manufacturers In manufacturing, IIoT can deliver (OPEX) and business intelligence
today are leveraging IIoT technologies improved traceability for better sup- efforts for customers, as well as cre-
to uncover inefficiencies in processes ply chain efficiency, which brings ate new business opportunities for
and turn them into working capital. about faster production and lower asset management, such as predic-
Therein lies the power and economic costs. Additionally, when todays tive maintenance, that enable vast
benefits of the IIoT. existing Big Data technologies for cost savings.
N a t i o n a l C o n t r o l s C o r p.
1.800.433.5700
Allied Electronics, Inc 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.
input #8 at www.plantengineering.com/information
IN FOCUS
Research, new initiatives are
highlights at MODEX
The biannual MODEX Show in Atlanta led by a diverse group of profession- PREST: Interestingly, we have seen
on April 4-7 will gather the top mate- als that utilize innovation, creativity some big shifts in adoption of some
rial handling experts from around the and smart thinking to not only drive technologies that just a year ago were
world. It also will be the showcase for operational efficiency but to keep the seen as emerging. We are learning
2016 MHI Annual Industry Report, economy going. that they are having a bigger impact
produced in conjunction with Deloitte much sooner than predicted. This
during a MODEX keynote on April 6. New and emerging manufacturing is proof that the accelerated pace of
George Prest, CEO of MHI, the asso- and supply chain technologies are change in our industry is dramati-
ciation for supply chain professionals, requiring highly-sophisticated skill- cally changing the way supply chains
discusses the upcoming trade event, the sets and an equally sophisticated, work and how they are managed.
2016 MHI Report and the impact of well-trained and well-paid workforce
the Industrial Internet of Things (IIoT) A big emphasis of this years report
on supply chain operations: Even though more than 11 million will be how this accelerated change
people work in the supply chain, 8.6% is only increasing the talent gap as
CFE MEDIA: One of the key points of the nations workforce, a shortage of these technologies, and the new
of emphasis at MODEX 2016 is the skilled supply chain workers remains. generation supply chains they are
future of supply chain. One area of An estimated 600,000 manufacturing creating, require a new breed of sup-
particular emphasis is finding and positions in the U.S. are unfilled for a ply chain professionals to run them.
training future workers. What is lack of qualified workers. In addition, The 2016 report will certainly be
the message MHI and the industry the U.S. Roadmap for Material Han- required reading for manufactur-
need to send to the next generation dling & Logistics predicts that by 2018, ing and supply chain professionals
of workers? there will be 1.4 million new jobs in who want to get their arms around
the logistics and supply chain field. these issues.
PREST: Supply chain careers are some
of the most rewarding and highly Because supply chains work behind the CFE MEDIA: Supply chain isnt top
compensated jobs that are now being scenes, you only hear about them when of mind in the discussions around
seen as the new path to the C-suite. there is a disruption. Through initia- IIoT, but what do you think are
tives like the IWorkInTheSupplyChain. some of the key opportunities with
We, as an industry, need to do a bet- com video campaign and the New this strategy for MHI members?
ter job of spreading the word that Generation Supply Chain Workforce
supply chains are global enterprises track at MODEX 2016, MHI is working PREST: The IIoT has the potential
to increase awareness of the amazing to deliver massive economic and
and rewarding career opportunities environmental rewards. It can boost
available in supply chain. productivity, drive new markets,
encourage innovation and result
CFE MEDIA: While the full industry in exponential change for industry
report will be presented at MODEX, and our society as a whole.
what are some of the key points of
emphasis in the new State of the The data and analytics generated by
Industry report produced by MHI the IIoT will provide opportunities
and Deloitte? to improve operational, resource
MODEX 2016
April 4-7, 2016 SHOW PREVIEW
Georgia World Congress Center, Atlanta
www.MODEXShow.com
The week will also feature MHIs Industry Night Celebration on April 6 with the Blues Brothers. Tickets to
this event are $50 and include beer, wine and hors doeuvres. A portion of ticket sales will be donated to the
Material Handling Education Foundation, Inc. (MHEFI).
and tie that data into operational asset unto itselfsomething that needs
models. to be studied and understood, not sim-
Bentley sees the process going ply collected. IoT is doing something
beyond information technology (IT) differently with data than youve done
and operational technology (OT). We before, he said. We can talk about
need to leverage the digital engineering connectivity and millions of sensors,
model, Bentley said. When we talk but its just about doing something dif-
about digital engineering models, were ferent with data. What were seeing first
talking about things like schematics, is the types of data are there, but its
3-D models, network models. We need hard to work with.
to go beyond IT and OT to engineering We all have biases, and we immedi-
technology, or ET. ately use our 30 years of experience to
At IBM, the challenge is to make sure say what we think is happening, Karns
the data is serving its highest purpose added. Where were moving with ana-
for customers. Thats not always just lytics is removing the bias. Were evolv-
data for the sake of data, said Pete ing to a much more powerful way of
Karns, vice president of offering man- using the data to help us look beyond Offering 10 Certification Programs:
agement for IBM. our own biases.
We know the data is there. Do we Rao said manufacturers need to u Substation Maintenance
start with data or start with what we prepare for this new era of data man- u Low Voltage Circuit Breaker
want to learn? he said. I see far too agementand warned that those who u Fiber Optics
many of our clients collecting the data dont will miss a huge competitive u Infrared Thermography Level I
without understanding what it is they opportunity. By 2025, 85% of manu- u Protective Relay Generation
want to learn. facturing will be connected, Rao said. u Protective Relay Basic
Karns said the Internet of Things If youre not on the bandwagon, you u Protective Relay Solid-State
(IoT) allows data to be viewed as an will lose your competitive advantage. PE u Protective Relay Advanced
u Medium-Voltage Cable
u Industrial Electrical Safety Inspector
input #9 at www.plantengineering.com/information
FIVE KEY CHALLENGES FOR IIoT INNOVATORS
IBMs Pete Karns identified five ways the Industrial Internet of Things (IIoT)
would impact both plant operations and data management. They include:
Camfil APC
Flexicon
FLIR Camera
Kaeser Compressors Inc.
SPM Instrument
Tekleen Automatic Filters
ADVERTISEMENT
C amfil APC offers the most
technologically advanced dust,
mist and fume collectors available
administrative functions and a
state-of-the-art test lab equipped to
conduct a battery of bench tests on
Tomm
backed by dependable service support dust samples, as well as simulated Frungillo
and decades of experience. Our full-scale testing. These scientific tests Vice president,
mission is to ship collectors fast while take the guesswork out of equipment Camfil APC
still giving the customer what they selection to help identify the best dust Americas
want; to be the most customer collection equipment for the job.
friendly company in the business;
and to make the best collector in the Over the past six months,
business from an end-user and Camfil APC has introduced
maintenance viewpoint. more new product lines than any
Over the past six
other year in months, Camfil APC
the companys
history. This has introduced more
expanded family of
products includes
new product lines than
our flagship line of any other year in the
Farr Gold Series
cartridge dust and companys history.
fume collectors
as well as mist
collectors, wet The latest addition is the Handte
Camfil APC corporate headquarters
Jonesboro, Arkansas
scrubbers and ancillary items all Vortex wet scrubber, which
designed to ensure a cleaner, combines high-performance wet
We guarantee our collectors to meet safer workplace. dust collection with easy plug and
EPA particle emission requirements. play operation.
We are also a leader in explosion The new Handte EM Profi emulsion
protection, with a full range of coolant mist collector for machining Its ideal for capture of very sticky
technical services to analyze centers offers very high collection dusts and fibers and highly explosive
combustible dust problems and efficiency and 24/7 performance. metallic, chemical and other dusts.
exclusive products to protect against Benefits include increased Because it provides wetting of
dust collector explosions. productivity, exceptional service combustible dusts, it can eliminate
ease and lower operating costs. the need for costly ancillary
We are a subsidiary of Camfil, the Service life is up to six years for the explosion protection devices.
largest air filter manufacturer in the primary filters.
world. All our components, including
filter cartridges, are manufactured in The Handte Oil Expert handles
ISO 9001 certified facilities. ultrafine, hard-to-capture oil mists
generated by machining processes
Our corporate headquarters that use pure (undiluted) lubricant
filterman@camfil.com
facility in Jonesboro, Arkansas oils. Both products come with a 1-800-479-6801
houses manufacturing, sales and 12-year limited warranty. www.camfilapc.com
ADVERTISEMENT
F lexicon Corporation engineers
and manufactures bulk handling
equipment from stand-alone units
Stand-alone equipment
The Flexicon line of stand-alone
equipment includes: Flexible Screw David Gill
to automated systems that are Conveyors, Tubular Cable Conveyors, President
integrated with new or existing Pneumatic Conveying Systems, Bulk
process equipment and storage Bag Unloaders, Bulk Bag Conditioners,
vessels throughout the plant. Bulk Bag Fillers, Bag Dump Stations,
Drum/Box/Container Dumpers and
Virtually any bulk solid Weigh Batching and Blending Systems.
material or blend Numerous model configurations Manufacturing on
Flexicon equipment can handle are offered within each equipment four continents
virtually any bulk material, from category, as basic, low cost units up Flexicon manufactures equipment
large pellets to sub-micron powders to engineered, automated, high- in the US, UK, Australia and South
including friable materials, free- and capacity machines. Africa, maintains dedicated factory
non-free-flowing products, and representation in Singapore,
materials that pack, cake, plug, smear, Large-scale bulk Barcelona and Chile, and also markets
fluidize or separate. After more than handling projects equipment and systems through an
20,000 installations, Flexicon is Customers can alleviate the burden extensive network of authorized
knowledgeable about virtually all bulk and risk of designing large-scale bulk representatives worldwide.
materials and blends that customers handling systems, coordinating
are likely to encounter. multiple suppliers, integrating The company holds 36 patents in 13
components and trouble-shooting countries, and in 2015 doubled the
Lifetime Performance Guarantee start-up, by relying on Flexicon for size of its US headquarters.
The Flexicon Lifetime Performance it all.
Guarantee assures customers of a
successful result, regardless of whether Flexicon can evaluate customer
they purchase one piece of equipment material(s), plant layout, through-put
or an automated plant-wide system, rates, cost, cycle times and other
providing added assurance that parameters, and engineer the optimum
customers can trust their process, solution to individual bulk handling
and their reputation, to Flexicon. problems in the form of CAD drawings
that integrate Flexicon and other
Designed and constructed to equipment with new or existing
industry standards worldwide equipment in the customers plant.
All Flexicon equipment is available in
carbon steel with a variety of durable In addition, Flexicon can test
industrial finishes, and stainless steel in customer materials on full-size test
industrial and food, dairy and phar- equipment, build the equipment,
maceutical finishes, including designed supervise installation, validate the
Flexicon Corporation
and constructed for 3-A certification project, and train customer personnel +1 610 814 2400 sales@flexicon.com
and USDA acceptance. to operate it anywhere in the world. www.flexicon.com
ADVERTISEMENT
T he start of a new year is a chance
to examine current processes,
look to the future, and plan for new
With this system data, we can
simulate power requirements of
different system scenarios using our
Frank
growth. At Kaeser, we continually Kaeser Energy Saving System (KESS) Mueller
look for opportunities to improve our in order to build the most energy
President,
operations so we can better serve our efficient system possible. Kaeser
customers, but never at the expense of Compressors, Inc.
our heritage. These compressed air audit tools
coupled with our unbeatable efficiency,
This heritage is built on nearly a simple maintenance, and rugged
century of manufacturing excellence reliability, result in a built for a lifetime
and holds reliability, efficiency, and system that is engineered to perform. Kaeser Compressors is committed
quality at its core. This commitment to providing our customers with
to excellence guides our engineering, Kaeser is not intimidated by demand- engineering excellence, the highest
design, and customer service principles ing applications. Our commitment in manufacturing quality, and cutting
and means we deliver solutions-based to designing the best engineered edge solutions.
systems of the highest quality. solutions results in compressed air
systems that remain Prompt and dependable customer
reliable even in service and engineering support are
the toughest of backed by extensive training and
applications in our ISO 9001:2008 quality assurance
the harshest of and ISO 14001:2004 environmental
environments. Thats compliance program. These all
why our customers contribute to the value our customers
know us as the air have come to expect from the
systems specialist. Kaeser name.
Kaeser Compressors, Inc. Headquarters in
Fredericksburg, Virginia
ADVERTISEMENT
need for expensive water-
treating chemicals.
ADVERTISEMENT
F or many years, plant engineers
have used thermal imaging
in their preventive maintenance
Typical FLIR thermal imagers for
route-based preventive maintenance
programs include handheld or
mechanical assets. Thermal sensors,
like the FLIR AX8, provide auto-
mated alarms when temperatures
programs to discover and measure point-and-shoot models. These exceed pre-set thresholds, as well as
heat generation in mechanical and models help maintenance profes- temperature trend analysis.
electric installations, machines, and sionals see and report equipment Paul A. Czerepuszko
compressors. Thermal imaging is an problems quickly, and have become With thermal imaging sensors like Director, Automation
effective technique to discover over- invaluable additions to the the AX8, FLIR continues to find new Business Development
heated components and to detect maintenance engineers toolbox. uses for its increasingly-more afford-
and prevent creeping breakdowns. able thermal imaging technologies,
By identifying problems before they Although regular route-based says Paul Czerepuszko, Director of new or existing installations.
become serious issues, thermal inspections, and spot checks for Automation Business Development. Digital inputs/outputs
imaging helps plant engineers save a troubleshooting are indispensable are available for alarms
lot of money. for todays preventative maintenance These sensors are specifically and control of external
programs, many plant managers designed for easy integration in a equipment and an image
need additional intelligence and production environment, and have a masking function enables
control over their equipment. These very small form factor, making them selecting only the relevant
managers are looking for real-time easy to install in space-constrained part of the image for analysis.
data, 24/7, 365 days in a year. areas. The FLIR AX8, for example,
is the only thermal sensor on the
In response to this growing need, market to incorporate industrial
FLIR offers cost-effective thermal communication protocols, like
paul.czerepuszko@flir.com
sensors for continuous condition EtherNet/IP and Modbus TCP/IP Tel: +1-866-477-3687
FLIR Systems, Nashua, NH monitoring of electrical and for easy setup and installation in www.flir.com
ADVERTISEMENT
E stablished in 1970, SPM
Instrument rates as one of the
earliest pioneering companies in the
The Shock Pulse Method,
(where SPM Instrument gets its
name) was revolutionary to what
developments and technological
advancements: wide spread use
of computers throughout indus-
field of Predictive Maintenance. was then the early stages of tries in the 80s, advancements
Vibration Analysis and Rotational in lubrication technology, digital Patrick Parvin
In the 1960s, rotational Equipment Monitoring. This signal processing, and micro Managing Director,
equipment monitoring consisted started a journey down a path circuitry with noise reduction. SPM Instrument Inc.
of putting a wooden rod or of developments in multiple
screwdriver to the ear and technologies used to perform Dedicated efforts over the years With qualified service
listening to a machine. Often what is now generally referred to to continually develop simpler and sales personnel
when a sound was heard, it was as Predictive Maintenance. and more efficient evaluation in over 50 countries,
already too late. A.P. Moller, a methods has enabled SPM we have the knowledge,
Danish ship owner, was not From 1970 until today, there to remain a top choice for instrumentation and
happy with the overabundance have been many industrial predictive maintenance, and solutions to support
of cargo pump failures with no machinery monitoring solutions. all of your predictive
forewarning throughout his maintenance needs.
tanker fleet. SPM recently released HD ENV
as proof to their continued
An inventor and enterprising commitment to technological
financier decided to address advancement. Products range from
the problem. In 1969, inventor high-tech, lightweight, portable
Eivind Sohoel patented the instruments, as well as online
www.spminstrument.com
first method for monitoring SPM Instrument Inc. North American systems, and a comprehensive info@spminstrument.com
rolling element bearings. Corporate HQ in Eugene, OR CondmasterRuby software. 1-800-505-5636
James Flaherty sees his companys first trip to Hannover Messe in Germany
as one giant step for his company, but also one major leap of faith for the
benefits this show might bring.
Flaherty is president and CEO of Adsorptech, a small manufacturer and
consulting company based in Middlesex, N.J. They make industrial-scale
oxygen-production equipment and provide gas-separation consulting services,
and until this year have never exhibited anywhere. Adsorptechs first foray to
Hannover Messe, the worlds largest industrial trade show, was facilitated by
the U.S. Commercial Service, a part of the Department of Commerce and a
partner in the companys expansion into Europe.
We look for distributors, and so heres a show where 25 countries will
attend, with a wide geographic spread, Flaherty said. Industrial-scale oxygen
is used in a multitude of industriesoil refineries, farms, and a lot of places
in between. If we went to shows in each industry, wed be doing nothing but
trade shows.
Adsorptechs relationship with the U.S. Commercial Service dates back 3
years to when the company first started to manufacture its products and was
looking at how to get started in the export market. So when the Commercial
Service suggested exhibiting at Hannover Messe as part of the United States
Partner Country status in 2016, Flaherty was interested in hearing more.
When weve worked with the U.S. Commercial Service, we had just decided
to export, and they helped us with the learning curve. They were the ones
who brought the show to our attention, said Flaherty. Its the first show I
saw that covered a lot of manufacturing, environment, and energy markets.
We can hit a group of our potential markets with one show. For a small busi-
ness, thats a perfect fit.
But with 6,000 exhibitors and more than 200,000 attendees at Hannover
each year, a significant concern was getting lost in the crowd. The Com-
mercial Service has helped with that. Were part of a bigger team, and thats
important, Flaherty said. Their value is, first, their advice. Being a newbie,
we have the greatest learning curve.
The company is working with the Commercial Service and the state of
New Jersey, which has provided some of the funding for the trip, to help make
connections to potential customers long before the show begins on April 23.
Theyre trying to determine which attendees are our would-be customers,
Making a splash
That support is a major reason why Kathy Wyrofsky, president of
International Products Corp. in Burlington, N.J., will be attend-
Adsorptech President and CEO James Flaherty never has ing her first Hannover Messe. The company has exports and
been to Hannover Messe, but said the support his company sales offices in London for its line of specialty industrial cleaning
is receiving from state and federal economic development products and specialty lubrication products.
groups means this first trip is likely to generate business. I walked the show about 15 years ago, but this is the first
Image courtesy: Adsorptech time weve been exhibiting, Wyrofsky said. The relationship
weve had with the Department of Commerce and their help
and are helping set up pre-show meetings. Were not just hoping with networking has been wonderful, and they brought the show
someone stops by. to our attention.
Its a really big opportunity to have meetings and network with
Commercial Service and its role potential partners, and thats a big reason to go, she added. One
The U.S. Commercial Service is a global marketing and consult- good prospect from a show pays for the show for us, and that
ing arm for small and mid-sized U.S. manufacturers looking to happens often. Ill be looking to take advantage of what the show
promote their products. There are more than 100 Commercial is offering in terms of meetings. I see an opportunity to connect
Service offices in the U.S. and a network of trade representatives with new customers as well as existing customers.
worldwide. Jim Higgins is president of Stay Online, a Creedmoor, N.C.,
Some of the key services we provide for U.S. manufacturers and manufacturer of power cords and plug adapters. Their products
other exporters are our trade counseling services to help companies are manufactured to North American and European standards,
understand the opportunities and value in exporting their goods and the company recently opened its first sales office in Prague.
and services, said Daniel Gaines, senior international trade spe- Stay Online has exhibited at vertical-market shows in Berlin,
cialist for the U.S. Commercial Service. They also offer a program Paris, and Amsterdam in the past, so this years foray to Hannover
called Business Matchmaking Services, which identifies qualified is hardly a first step into Europe.
overseas partners as well as an ongoing series of trade missions to But Higgins appreciates the difference between American and
markets around the world. European trade events and business practices, which is why an
Hannover Messe is a regular event for the Commercial Ser- appearance at Hannover is important. In Europe, some relation-
vice, but with the U.S. being Partner Country in 2016, it affords ships are predicated on meeting the person, Higgins said. Over
the Service a starring role in this years show. The U.S. Pavilion the course of a month, Ive had two business meetings in airports.
at Hannover will be an important hub for both U.S. states and For some people, its about, Im not going to do business with
manufacturers looking to expand exports and attract foreign direct you until I meet you.
investmentand a place for European and Asian businesses to They also respect a product that is well-made, Higgins added.
learn more about U.S. opportunities. I love working with the Germans; with them, theres no gray
Gaines said the Commercial Service will offer U.S. exhibitors area. They will tell you, Heres what I need in order to do busi-
at Hannover Messe support in four areas: ness with you.
Preshow educational webinars to help companies prepare for
the event U.S. manufacturing in expansion mode
Preshow company promotions to potential overseas partners, While the global manufacturing sector has slowed after a 4-year
helping U.S. exhibitors get maximum exposure to the potential advance, Commerce Department officials are bullish about the
buyers, partners, and investors at the show U.S. leadership role in global manufacturing. U.S. manufacturing
On-site executive marketing counseling with commercial is adding jobs at its fastest rate in decades, with nearly 900,000 new
experts from U.S. embassies from across the globe, helping manufacturing jobs created since February 2010; and manufactur-
U.S. exhibitors create custom strategies for approaching key ing production is up by almost one-third since the recession. The
global markets number of factories across the United States is growing for the first
The relationship weve had with the Department of Commerce and their
help with networking has been wonderful, and they brought the show to
our attention.
Kathy Wyfrosky, International Products Corp
time since the 1990s, where EXIM will extend credit to a U.S. manufacturers overseas
said Deputy Assistant buyer, which can unlock financing otherwise unavailable to a
Secretary of Commerce foreign buyer seeking to purchase U.S. products. In addition,
Antwaun Griffin. EXIM offers other insurance and financing options to help
For small and mid- minimize the risk in doing business overseas.
sized manufacturers,
there are many resourc- The first step that any manufacturer interested in growth should
es offered through state do is visit www.export.gov and contact their nearest U.S. Com-
and federal programs to mercial Service office, Gaines said. That office will be able to
encourage expansion of manufacturing exports and the opening meet with the company and walk them through the resources
of new markets. They include: across the U.S. government that will be of the most value to their
specific company.
STEP Grants: The Small Business Administration (SBA)
awards state governments with federal money known as STEP Managing expectations
Grants, which act as a strategic investment to help small to For first-time attendees at Hannover Messe, the chance to be part
medium-sized companies expand their international reach. of the U.S. delegation at the show, interact with global manufac-
These funds can be leveraged to help offset export-related turing partners, and expand their business all are compelling
costs, such as trade shows, travel on a trade mission, or using drivers.
a U.S. Commercial Service fee-based service If we get one order, its worth it, said Flaherty. Our products
Export Working Capital: SBA provides advances of up to $5 are high-capital expenditures products. One is not a very big num-
million to fund export transactions, from purchase order to ber, but our expectation is thats the lowest number well have.
collections. The working capital can support foreign accounts If that does happen, Flaherty said the Commercial Services
receivable during long payment cycles or can be used to finance efforts to point them to Hannover Messe would get a good part
suppliers, inventory, or production of export goods or services. of the credit. If I saw this online, I would not have recognized
This loan has a low guaranty fee and quick processing time. the value, Flaherty added. They said we think this fits you,
Foreign Buyer Financing and Accounts Receivable Insurance: and heres why.
The Export-Import Bank (EXIM) offers a variety of financial We feel really good about U.S. manufacturing, said Higgins.
tools that U.S. companies can leverage to support their export If your product fills a niche and brings value, theres a market out
operations. One example is their foreign buyer credit service there. If you apply your imagination, there are opportunities. PE
LOCATION: For the first time, the United States will be the Partner Country at Hannover Messe
Hannover, Germany 2016, which will highlight the U.S. role as the worlds leading manufacturing econo-
my. The U.S.-based Industrial Internet Consortium (IIC) will present itself at a special
DATES: display area. IIC promotes the development of the Industrial Internet of Things (IIoT).
April 25-29, 2016
The show also will highlight the emphasis on Industrie 4.0, which focuses on
HOURS: concepts similar to IIoT. The focus is around data management, which will highlight
9 a.m. to 6 p.m. the use of predictive maintenance, machine and plant engineers embed sensors in
machinery so that it can independently indicate that it will soon require servicing.
WEBSITE: Using this data, the machinery manufacturer can build his after-sales business by
www.messe.de offering timely maintenance services to factory operators.
Winner
2015
Make it smooth
Hannover Messe on April 24
By Bob Vavra, Content Manager, CFE Media
President Barack Obama will lead Hannover Messe officials said that to
the United States delegation to Han- date, more than 250 U.S. manufactur-
nover Messe 2016 on April 24 to high- ers have signed up to exhibit. The U.S.
light the U.S. role as Partner Country at Department of Commerce also is work-
o
the global manufacturing trade show. ing with American manufacturers look-
Hannover Messe 2016 is April 24-29 ing to make contacts with prospective
in Hannover, Germany. partners in Germany and Europe.
The White House confirmed Presi- The President will join German Chan-
dent Obamas participation in Han- cellor Angela Merkel at the opening cer-
nover Messe in an announcement Dec. emonies at Hannover Messe on Sunday,
30. The Presidents participationa April 24 at the Hannover Centrum. The
first for a sitting U.S. Presidentpres- event traditionally features a cultural
ents an unique opportunity to show- presentation by the Partner Country. On
case American innovation and ingenu- Monday, April 25, Obama and Merkel are
ity and to highlight the United States expected to tour the fairgrounds and visit
as a prime investment destination, a number of trade show booths. PEAK AND INRUSH
the White House press office said in a This visit, which will be the Presi- CURRENT LIMITATION
release. While in Germany, the Presi- dents fifth to Germany, underscores SPIKE PROTECTION
dent will address efforts to advance the enduring political and economic
negotiations on the Transatlantic Trade ties between Americans and Germans HIGH RELIABILITY
and Investment Partnership.
Hannover Messe officials were
and highlights the U.S. commitment to
trade and investment as drivers of job 480 V
delighted by the announcement. Pres- creation and economic growth on both
ident Obamas participation sends a sides of the Atlantic, the White House The new line reactor LR3 48 series
special signal about Hannover Messes said in a statement. mitigates harmonics and smoothes up
international appeal, said Dr. Jochen The President will continue the tradi- your systems.
Kckler, member of the managing tion of heads of state attending the open-
board at Deutsche Messe AG. And ing ceremonies when their nations were
Hall 13
the timing is perfect: in the midst of selected as Partner Country. In 2012,
Booth C34
its reindustrialization the United States Chinese premier Wen Jiabao opened
has become a very attractive business the event and in 2013, Russian president
partner for industry. For German Vladimir Putin addressed the opening
machinery and plant manufacturers, ceremonies. Indian prime minister Nar-
the USA is once again the number one endra Modi appeared at the 2015 opening
market. ceremonies. PE
F L I R.c o m / T 1 K
Salary Survey
B
efore the calendar turned, 2016 already Manufacturing is still seen as a secure career by
had the makings of a pivotal year for more than two-thirds of respondents; and 65% of
manufacturing and for the world. all respondents are over the age of 50, indicating
There were the big events for the year, experience still is a key factor in manufacturing
including the United States as Partner management.
Country at Hannover Messe in April That experience is being rewarded. Average
and the 2016 International Manufacturing Tech- base salaries climbed to more than $100,000 for
nology Show (IMTS) in Chicago in September. the first time in the Salary Survey, and 46% of
Theres also the matter of the U.S. presidential respondents said their base salary was higher
election in November, which promises than that $100,000 threshold. There also
to shape policy in manufacturing for is optimism around salaries for 2016,
years to come. as 69% saw pay increasing this year.
But the year started with global Some respondents cited global
economic turmoil, as a slowdown unrest as a concern for manufac-
in Chinese manufacturing trig- turing. Others are anxious to see
gered a worldwide stock hiccup government regulations relaxed,
that sent values plummeting. both on their operations and in
The continued plunge in heath care. Some still see barri-
world oil prices has resulted ers to growth within their own
in a slowdown in exploration plants; thus, within their own
and, by extension, the manufacture control. Everyone, it seems, is worried
of exploration equipment. about something.
Despite the relative strength of the U.S. In 2015, the year began with confidence and
manufacturing market, the monthly PMI Index optimism. In 2016, the year begins with uncer-
put out by the Institute for Supply Management tainty. The issues that face manufacturing in the
declined for seven straight months and fell into short-term are complex and outside of the con-
contraction for the first time in three years in trol of most individual plants. That makes it even
November. more important to focus on those areas of your
These are nervous days. facility you can controlsafety and productivity,
Thats why it is not surprising that for the first training and employee development. If we dare to
time in a decade, the primary concern of plant look back at 2008 and what followed, we can be
managers is the economy, according to the 2015 reminded of those qualities that led U.S. manufac-
Plant Engineering Salary Survey. In past years, the turing forward and brought the overall economy
top issue was the lack of a skilled workforce, and from recession to prosperity.
that checks in as managers second-largest issue,
but the economy was clearly a bigger concern at Bob Vavra
the end of 2015. Content Manager, Plant Engineering
Associates
degree
Trade/technical 8%
Doctoral
school diploma Dual bachelors degree
5%
High school degree 2%
diploma 3%
3%
2015 2014
2015 2014
2015 2014
2015 2014
SOUTHEAST
$93,577
$90,943
SOUTHWEST
$116,336
$105,161
2015 2014
2015 2014
Decrease
Increase 4% to 6%
2%
Increase more than 6% 10% Increase more than 6% Increase 4% to 6%
4% 3% 7%
58%
Personal performance*
CONSIDER MANUFACTURING TO
BE A SECURE CAREER
No
Yes
40%
60%
Economy* 23%
Analyst outlook
CHATHA: ARC is predicting another gloomy year for The global automotive industry also saw good growth
manufacturing due to both the modest global growth in 2015 due in part to increased consumer confidence
expected in light of the slowdown in China, Brazil, and and lower gas prices, which stimulates sales of less ener-
Russia and the continued depressed oil prices, which gy-efficient, but typically much more profitable larger
will continue to reduce capital expenditures across a and luxury vehicles. Automotive manufacturing is also
number of key industrial sectors. going through a transformation through digitization and
robotics, which are increasing value for consumers and
CFE MEDIA: Manufacturing was in a slump at the end of reducing design and manufacturing costs and increasing
2015. What are the driving factors for manufacturing production flexibility.
going forward that will pull out of that slump?
Were also seeing a big focus on general manufacturing
CHATHA: We expect the slowdown in manufacturing to innovation driven by new technologies such as IIoT,
continue at least through the first half of 2016, especially additive manufacturing, robotics, and so on. Most manu-
facturers now realize that they must transform their on the plant floor, throughout an industrial enterprise,
operations through new information-driven technologies and across a global value chain.
and approaches to survive.
CFE MEDIA: We talk a lot about IIoT, globalization,
CFE MEDIA: Everyone is hearing about IIoT. Why should safety and productivity. Whats the one big issue that
IIoT be important to manufacturers? you think manufacturers should talk about that doesnt
get a lot of attention?
CHATHA: ARC believes that the Industrial IoT, Industry
4.0, Smart Manufacturing and other initiatives will drive CHATHA: Due to the short-term, bottom-line mentality
a transformation in manufacturing. IIoT connects pre- of many manufacturing enterprises, I dont believe that
viously stranded data from smart sensors, equipment, the need to invest in and exploit innovation gets nearly
and other industrial assets with predictive analytics and as much attention as it deserves.
other advanced applications running both
in-plant on edge computing devices and
remotely in the cloud.
Despite initial concerns, many companies now realize that, when properly
implemented, Internet-based technologies can provide appropriate security
and availability. This further increases collaboration on the plant floor.
Andy Chatha, ARC Advisory Group
Image courtesy: ARC Advisory Group
Analyst outlook
Talent-driven innovation could be a key differentiator
The United States is expected to become the most competi- CFE MEDIA: Its a long time until 2020. What could keep
tive manufacturing nation over the next five years, with the the U.S. from achieving this top competitiveness ranking
current leader China sliding into second position, accord- between now and then?
ing to the 2016 Global Manufacturing Competitiveness
Index report from the U.S. Council on Competitiveness RODRIGUEZ: A new global competitive environment is pre-
and Deloittes Global Consumer & Industrial Products senting Americas leadership with fresh and persistent chal-
Industry group. lenges. While we are seeing positive movements like strong
demand from global markets, more cost-competitive energy
The 2016 Global Manufacturing Competitiveness Index prices, a fading labor rate arbitrage, and significant growth
shows the importance of policy, investment, and innova- through innovation, there are still a number of areas that
tion for company and country-level competitiveness, said executives cite as challenges. Things like a significant talent
Deborah L. Wince-Smith, president and CEO of the U.S. shortage, the widening skills gap, as well as the high cost and
Council on Competitiveness. Its findings help companies complexity of compliance in an uncertain U.S. regulatory sys-
shape their business strategies in order to compete success- tem all present unique hurdles in achieving the top ranking.
fully, and create jobs.
CFE MEDIA: In a global manufacturing economy, where should
Michelle Drew Rodriguez, manufacturing leader for Deloitte the U.S. focus its attention as it looks to continue to grow?
Services LPs Center for Industry Insights, discussed the find-
ings of the Advanced Technologies Initiative: Manufacturing RODRIGUEZ: Its simple: Talent and innovation. Talent-driven
& Innovation report and Deloittes view of manufacturing innovation could be a key differentiator going forward as
heading into 2016. manufacturers shift to higher-value advanced manufactur-
ing. This could aid in creating premium products, processes,
and services that capture higher margins and help sustain a open their doors and
competitive advantage. And to continuously innovate and showcase innovative
grow, companies will likely need to compete for the best and approaches to push-
brightest minds around the globe. ing scientific advances
like self-driving cars,
CFE MEDIA: While technology is a huge driver for com- renewable energ y Image courtesy: Deliotte
petitiveness, so is talent. What should the U.S. be doing sources, and molecular-
to bring more manufacturing talent into the pipeline? level products. We should open the eyes of up-and-coming
talent to the wealth of amazing possibilities within manu-
RODRIGUEZ: A strong manufacturing industry is fundamen- facturing.
tally vital to the prosperity of a nation. Therefore, we should
do more to attract, recruit, and retain the highest caliber of CFE MEDIA: Given the globalization of manufacturing, is
talent to work in manufacturing. But in the U.S., manufac- Made in the USA still a viable idea?
turing still faces a perception issue.
RODRIGUEZ: Absolutely. Now, probably more than ever, the
As a nation, we should raise awareness and visibility that strength and vitality of our U.S. manufacturing industry,
this is no longer your grandfathers factory. We need to help coupled with our innovative ecosystem and entrepreneurial
students understand the breadth of high-tech, high-skill, drive, positions us well to design and build the next genera-
and high-paying jobs manufacturing offers. For the past tion of products here in America; products that will serve
several years, Deloitte has been a key sponsor of efforts such the global market. Its truly an exciting time and place to be
as Manufacturing Day, a standing date when manufacturers in manufacturing.
product quality from design
Companies will maintain profitability but free cash will efficacy to supplier performance
continue to go into dividends, stock buy-backs, or to production quality and on to
aftermarket activities. The inte-
acquisitions rather than new plant and equipment. gration of the Operations Tech-
Bob Parker, IDC nology (OT) and Information
Technology (IT) organizations
is an issue as well.
A recipe for
long-term growth
In the middle of America, a salad dressing plant mixes automation
and people in just the right amounts.
T
By Bob Vavra he aroma of more than 200 ingre- the nickname Little Tulsa of Illinois. In
Content Manager, CFE Media dients comes at you as soon as you the 1920s, Charles Lindbergh became close
enter the storage area at the Pinnacle friends with a St. Elmo resident, and a house
Foods plant in St. Elmo, Ill. The indi- was constructed there in Lindberghs honor
vidual spices, herbs, and oils cannot in 1927 after his famous trans-Atlantic flight.
be identified as you take that first After Lindberghs return to the U.S., he made
breath. They will be combined soon into one of St. Elmo one of the stops on his national pro-
19 different formulas of Wish-Bone salad dress- motional tour.
ing on the new processing line at Pinnacle. Today St. Elmo is a rural enclave, and the Pin-
A separate area of the plant manages the aller- nacle plant is both its largest employer and its
gens that also go into salad dressing production most prominent landmarkso much so that a
eggs, dairy products, and the like. They must be sign reading Plant Entrance is on the signpost
handled differently, and kept separate from the that greets you as you exit I-70.
other ingredients until its time for production. It is a central location, with I-70 and I-65
Its all about following the recipespecific crisscrossing in nearby Effingham, allowing for
ingredients in precisely the right amounts mov- easy distribution of the products in all direc-
ing through the stainless steel system to ensure tions. It also has proven to be an efficient plant
quality and purity. for Pinnacle, which manufactured Open Pit
Its a complicated batching business, said barbecue sauce and Mrs. Butterworth and Log
Thomas Perkins, plant manager at the Pinnacle Cabin syrups before the Wish-Bone acquisition.
Plant in St. Elmo. Hes talking about the combina- Pinnacle Foods invested a reported $50 mil-
tion of both process and people that led Pinnacle lion in the St. Elmo plant, but for Perkins and
Foods to locate the Wish-Bone production in his team, the investment in people was just as
St. Elmo after the company acquired the brands crucial to the quick success the Wish-Bone
from Unilever in 2013. Weve significantly line has generated in less than a year of formal
invested in the process. But it also depends on the operation.
organizationhow we hire people, train people, The company bought this brand because
the value of formal training, how we conduct they expected to grow it, and this plant was
daily business. We use exacting amounts. built with the idea to grow it, Perkins said. We
He paused, then added, Theres a lot to be have a very solid continuous improvement pro-
said about using exacting amounts in the salad gram. We started at 60% of capacity, and we
dressing business. can grow the other 40% without expansion. We
have room within the facility and within the
A central location currently installed equipment.
St. Elmo is a blip on Interstate 70 through To bring on additional staffthe plant grew
central Illinois. Just 1,400 people call it home, from 85 workers at the time of the acquisition
yet it has not been completely overlooked to more than 200 todayPerkins said he relied
in history. An oil boom hit the area in 1938, on a strong community base within 30 miles of
and the number of residents and oil wells the plant and a strong combination of people
both reached nearly 2,000, earning the town and process.
Valve Automation/PVF
Supply Chain Services
Fasteners/OEM
seweurodrive.com / 864-439-7537
S
By Navneet Vinaik mart meters are integral to a growing the measurement of power (or gas or water)
Littelfuse Inc. number of industrial utilities applica- consumption as well as for handling the
tions, including gas and water meters, communication and other smart functions
energy management, and others. required. As their complexity increases, so
Smart meters offer a wide variety of advan- does their vulnerability to circuit threats
tages for both utility companies and their like transients, electrostatic discharges,
customers, including support for real-time power quality disturbances, etc. To ensure
billing, fault identification and management, these meters continue to work, even in hos-
load-side demand monitoring and manage- tile operating conditions, robust circuit-
ment, theft/tamper detection, and demand protection technologies are essential.
analysis. Different types of smart meters will face
The in-depth data these meters provide various threats. For example, the biggest
allow utility companies to monitor energy threats to electricity meters are input tran-
usage, control demand usage by remote con- sients and power line disturbances. Howev-
nect/disconnect, identify tampering and er, water and gas meters need protection for
raise alarms, etc. Utility companies also can their batteries. Similarly, energy-monitoring
give users advance warning of upcoming/ devices that have a human-machine inter-
unscheduled power outages and restorations, face (HMI) need to be protected against
and diagnose and correct problems before electrostatic discharges (ESDs). All of these
meters fail. In addition, smart meters provide systems employ different communication
customers much of the information needed to interfaces, and many of them also need cir-
perform real-time usage analysis so that they cuit protection.
can begin controlling their usage in a timely The following section investigates the
way, understand power quality, and protect specific protection requirements for each
the connected loads in case of overvoltages block of the smart meter solution shown
or overloads. in Figure 1.
Input power supply section: If its an elec-
Complex circuits require protection tricity meter, then it is powered by input
Table 1: Communications Smart meters are bidirectional, commu- mains, which are highly prone to high
port protection. All graphics nication-based devices that incorporate energy transients arising from lightning
courtesy: Littelfuse complex electronic circuits for controlling or grid disturbances. Metal oxide varistors
(MOVs) are used to pro-
tect against these transient
SIGNAL SPEED SIGNAL LEVEL DEVICE TYPE
surge events. To protect the
Asymmetrical, mid-high wiring from fire hazards in
RS-232/RS-485 Low 2-channel: -7V to +12V
capacitance device can work case catastrophic damage
Low capacitance, 2- or 4- in the power supply causes
Ethernet High 2/4 Channel: 5V a short circuit, a fuse is also
channel low voltage device used at the power supplys
Low capacitance, 4- or 5- input front end.
GSM/GPRS High 4/5 Channel: 3.3V/1.8V channel device for SIM card Mete r ing e ng ine sec-
protection tion: A microcontroller or
digital signal processor is
Power Line Low-mid capacitance device, typically used for energy
Variable 1- or 2- channel: +
15V
Communication depends on actual speed measurement and process-
ing purposes. Although
Figure 1: Smart meter block the power supply to this microcontroller power line communication (PLC) or optical
diagram. is protected from transient surges, the ana- ports. Because each of these port types has
log signal-sensing pins of the microcon- different operating speeds and specifica-
troller are still connected to the input supply tions, they will need different protection
for measurement of voltage and current. schemes.
Although these signal pins normally have Tamper detection: Utility companies use
a high value of resistances and capacitors smart meters to track usage so they can
connected for filtering purposes, some fast- charge users for their consumption. How-
rising transients can pass these filter stages ever, this causes some users to try to tamper
and reach the microcontroller, which is very with the meter and manipulate the read-
sensitive to transients. To prevent damage ings. As a result, these meters are typically
to the microcontroller, very small transient- designed with a host of tamper-detection
protection diodes are used on the signal techniques.
pins to clamp any incoming transients to The simplest, most common tampering
safe levels. technique is to open the meter cover and
Communication ports: Depending upon damage it. By using a reed switch with a
the meter application, a number of com- magnet or microswitch in the design, this
Figure 2: TMOV and iTMOV munication ports might be used, includ- sensor detects when the cover is opened
circuit protection. ing RS-232/RS-485/Ethernet/GSM-GPRS, and sends a trigger to the microcontroller.
Line
Line Fuse
2
To Protected Circuit
Thermal
Fuse Diode
Element
i TMOV Normally ON
Monitor
3 Lead LED
MOV
3
R
1 2
1
Neutral
Outlet
N S
Water
Inlet Flow
After recognizing the tamper attempt, the Specific protection requirements Figure 3: Meter application
microcontroller notifies monitoring support Electrical power meters are susceptible to using a magnetized encoder
staff at the utility company who, in turn, input transients and surges generated either and reed-switch sensor.
can impose a tampering penalty on the user. by lightning events or power quality distur-
Another method of meter tampering bances. These transients, which can reach
involves bringing a magnet close to the 30 kV in magnitude, depend on a variety
meters body, which can either cause the of factors including geographical location,
magnetic transformer to saturate or affect types of loads connected in the vicinity, etc.
other components. When a Hall effect sen- MOVs are primary devices used for protect-
sor is employed in the design, it detects the ing against these surges. The required level
field of the magnet and gives a trigger to the of surge immunity dictates the rating and
microcontroller to record the tamper event size of the MOV. For basic surge protection
and inform the utility company. between 2 kV and 4 kV, a 14-mm MOV
Another severe tampering technique might work. However, for protection levels
involves causing an ESD discharge to the of 30 kV, a larger 32 or 34-mm MOV might
meter body using a spark plug or CRT-EHT be needed.
generator. In this case, the meter enclosure Because they are passive devices with lim-
is made using plastic to fully isolate the elec- ited lifetimes, MOVs have several inherent
tronics circuit from the external world and problems associated with their end-of-life
minimize the impact of this ESD discharge. stage. For example, once they reach their end
The microcontrollers power supply and sig- of life, they can cause damage to themselves
nal-sensing pins will have ESD protection and pose a threat to their electronic circuit.
diodes to protect the microcontroller from The MOV can withstand only so many surge
any ESD discharge that still gets coupled to strikes before failing, and this surge strike
it. With the first two tampering techniques, capability depends on the MOV disc size
the microcontroller can send details on the and the magnitude of the surges the MOV
tampering attempt to a control/monitor- is designed to absorb.
ing station for assessing a penalty or just So, while selecting an MOV, along with
to protect the meter from getting damaged. considering the peak surge immunity needed,
Auxiliary power supply section: Smart its also important to take into account the
meters sometimes have an extension unit systems expected lifetime. For example, con-
that goes into the users home while the sider a system thats meant to last 5 years
main meter is installed at a centralized and requires 6 V protection. Even if a 20-mm
location in the building. For these appli- MOV might meet a 6-kV/3-kA, 15-strike cri-
cations, the home extension unit may have teria, a 25-mm or larger MOV would be used
a Power over Ethernet (PoE) adapter. This to provide the ability to withstand more surge
communication cable requires additional strikes over the lifetime of the meter. Ade-
protection because it can be susceptible to quate derating of the MOVs used is needed to
induced surges in the building. ensure the system lasts for its desired lifetime.
Current
Sensing SIM Card
GPRS ESD
Protection
Surge
Protection ESD and
Voltage Microcontroller PLC Surge
Sensing Protection
NL
ESD and
RS-485 Surge
Protection
Figure 4: Tamper detection Some of the newer specifications also lithium-ion (Li-ion). Because these batter-
for when a cover is opened. require that these MOVs are protected against ies have significant capacities, a normal or
end-of-life failures. For these applications, a resettable fuse is used to protect against
thermally protected MOVs (TMOVs) are short-circuit failures caused by faults in the
used (Figure 2) to continue protecting the circuit.
circuit during their lifetime. Once they reach The most critical resource in these meters
the end-of-life stage, they disconnect them- is the battery life, which must be preserved
selves from the circuit to prevent catastrophic and protected to extend the life of the meter.
damage. TMOVs can also have an indication These meters derive their sensing signal
feature to alert the meter that the protector from a magnetized encoder and by using a
has failed and needs replacement. reed-switch sensor; the signal is fed to the
microcontroller (Figure 3). The smart meter
TMOVs have an integrated thermal fuse can be designed so that the microcontroller
TMOVs ensure that the MOV is discon- turns on only when the reed switch senses a
nected from the supply when it reaches pulse. After it records the pulse count, it goes
end-of-life stage. back into sleep mode, which helps extend the
Indicating TMOVs (iTMOVs) also indi- battery life so that the meter can last longer.
cate when replacement is required.
In designs where fast-rising transients can Designing a smart electrical power meter
also damage the power supply section, tran- To illustrate the process involved in design-
sient voltage suppression (TVS) diodes are ing a single-phase smart electrical meter,
often used in conjunction with MOVs. These consider an example using the following
devices clamp the fast-rising transients while specifications:
the front-end MOVs absorb the bulk of the
high energy in those transients. Input surge protection
Meters used in water and gas utility appli- Combination wave: Differential mode 15
cations normally have a fixed internal bat- strikes of open-circuit voltage (1.2 S/50
tery that is sized to last for 5 to 10 years. The S) 10 kV with short-circuit current (8 S/2
most commonly used battery chemistry is 0S) 5 kA
I
By Lyle Meyer n todays manufacturing landscape, com- starting at about 40% more for the initial
Eaton panies and their facilities face enormous purchase of an electric machine as com-
pressures to increase operating efficiency pared with similar hydraulic injection
while reducing their carbon footprint. molding machines.
Feeling the heat from both increasingly By combining the affordability and util-
stringent government energy regulations and ity of hydraulic injection molding machines
customers seeking lower operating expenses, and the energy savings of electric machines,
manufacturing facilities across every industry hydraulics can add to the value proposition
demand increasingly energy-efficient power- of electronic technologies. Adding a VSD
management solutions. provides a bigger advantage, as compared
Regulations have impacted facilities down with only increasing motor efficiency, and
to the motor level, and variable speed drive opens possibilities on the hydraulic system
(VSD) technology has been applied over the side through less expensive, fixed-speed
years to help power systems like injection pumps that operate more efficiently.
molding machines operate more efficiently. VSDs smooth incoming electric-line
The injection molding industry has served power to further increase motor efficiency.
as a starting point for applying VSD solu- VSD systems regulate flow by changing the
tions in combination with traditional fixed shaft speed, so no valve throttling is required
and variable-displacement hydraulic pumps, in most applications. Reduction in throttling
which allow customers to gain more control loss is the major reason for VSD systems
throughout the duty cycle. higher efficiency. A small portion of ener-
gy savings also comes from the efficiency
Hydraulic and electrical integration improvement of the electric motor.
Electric servo drive technology has been Overall, energy savings of up to 70%
making inroads for some time, penetrating (depending on the duty cycle) can be
into factory automation because of per- achieved with VSD pumps as compared
ceived energy efficiency, faster response, with conventional pumps. VSD pumps also
and better precision and repeatability. How- provide a significant reduction in sound,
ever, costs for electric injection molding because the motor and pump speeds change
machines were substantially higher than throughout the duty cycle instead of main-
hydraulic injection molding machines, taining constant speed.
With a VSD, a proven, fixed-displacement
vane pump is made significantly more effi-
cient, allowing manufacturers to buy a less
Looking at complete machine design, rather than expensive pump to achieve the same results.
VSD technology in some applications
individual components, allows machinery across uses servo-performance electrical motors
the manufacturing industry to benefit from the to control the hydraulic instantaneous flow-
rate throughout motor-pump shaft speeds.
new solutions. The result is a power-on-demand pump unit
thats free of the throttling losses that typi-
cally account for significant loss of power.
The variable speed drive Servomotor dynamics also enable closed- motor can be 2% more efficient, this may
integrated with a servo loop hydraulic motion control, thereby sim- eliminate the long-term need for creating
motor and pump provides plifying system architecture design. more energy-producing facilities.
manufacturers a closed-loop Throughout the manufacturing process,
dynamic motion control Driving manufacturing efficiency energy is wasted due to inefficient equip-
capability that operates Manufacturing is facing changes, and com- ment and mechanical and thermal limita-
as a cost-effective, high- panies need to adapt to new government tions. Optimizing the efficiency of these
performance solution. Image regulations. systems can result in significant energy and
courtesy: Eaton With new energy standards initiated in cost savings.
Europe and implemented worldwide over
the past few years, its not only more cost- Embracing the market pressure
effective to increase motor efficiency, its Manufacturers are seeking to retrofit exist-
also frequently required by law. Government ing machines for improved efficiency to
regulations are requiring higher efficiencies both meet regulations and lower costs, leav-
at the electric motor level, and sometimes ing factory owners and operators with two
a more efficient electric motor is just not options:
enough. A new motor must be 2% more Retrofit systems with more efficient elec-
efficient than previous models. While that tric motors or install new machines with
sounds small, consider this: If every electric improved motors
In hazardous areas
sensor safety rating is crucial
Appropriate selection is critical to proper position-sensing-system deployment.
A
By Matt Hankinson significant proportion of industrial equipment being severely damaged or even lives
MTS Sensors equipment will be deployed in hazard- being put in danger.
ous areas, or possibly applications that In hazardous areas, the presence of flamma-
require a functional safety assessment. ble gas, vapor, liquid, or dust can bring major
Hazardous areas include locations where there risk to the activity of an electrical device, as
is the risk of exposure to flammable or even there is the prospect that the device could ignite
explosive substances. In such circumstances, the flammable substance. For equipment incor-
ensuring ongoing operation can prove to be porating position-sensing technology, the con-
challenging. It is, therefore, critical that the stituent sensor device (or devices) should have
component parts that make up such items of appropriate features to address these issues.
equipment are suitably constructed to function Before performing an in-depth study, it
in these uncompromising environments. must be made clear that hazardous-area-rated
Functional safety applications are ones in devices are designed to operate in a potentially
which safe operation must be ensured due to the explosive environment while functional safety
risk of equipment damage or personal injury. products are designed for applications where
Linear-position sensors are widely used in all there is risk to equipment or people. These two
manners of industrial systems. In many cases, parameters are not necessarily interrelated. An
the potential for hazardous events occurring application might require either a functional
needs to be taken into account; otherwise, the safety or a hazardous-area rating without neces-
consequences could be seriouswith expensive sarily requiring the other.
- ENVELOPING
- a new era in vibration monitoring
Do you have questions and
www.spminstrument.com
www.cemanet.org
5672 Strand Ct., Suite 2 Naples, Florida 34110 239-514-3441
input #23 at www.plantengineering.com/information
Furthermore, oil, grease, and other
substances often found in heavy indus-
KEY WORDS:
trial environments mean that they will Here are some of the articles at www.plantengineering.com,
require cleaning and maintenance work KEYWORD: SENSORS that further discuss this topic:
on a regular basis (all of which adds to
the running costs). MOTION TRENDS TO WATCH IN 2016
Technology trends today are all about connectivity and the gains to be had from infor-
3. Linear variable differential trans- mation gleaned from an increasingly connected world. Staying ahead of the techno-
former (LVDT) devices: LVDTs rely logical curve is more important that ever. Trends that manufacturers should be taking
on the movement of a ferromagnetic a close look at in 2016 include big data, predictive maintenance, the Industrial Inter-
core that varies the magnetic coupling net of Things (IIoT), and smart energy monitoring for transparent factory operations.
between primary and secondary coils.
Thanks to their high temperature rat- WIRELESS INTRUSION DETECTION AND PROTECTION SYSTEMS
ing, these devices have seen fairly wide- Wireless intrusion detection systems (WIDS) and wireless intrusion protection sys-
spread deployment in hazardous areas. tems (WIPS) are used to continuously protect a wireless network and in some cases,
However, they exhibit an intrinsically a wired network, from unauthorized users. There are some basic differences between
poor linearity. Also, they need to be the two systems.
recalibrated periodically.
FIVE TIPS FOR IMPROVING HYDRAULIC CONTROL IN A MECHATRONIC SYSTEM
4. Magnetostrictive linear sensor Modern hydraulic drives are an integral link in the mechatronics chain and a vital
devices: Using the principles of mag- element in overall Industrie 4.0 machine concepts. However, working with hydraulics
netostriction, where a magnetic field poses a number of challenges, based on physical properties and limitations that need
can alter the physical properties of a to be addressed. Be sure to consider these important tips to improve functionality and
ferromagnetic material, magnetostric- performance when incorporating hydraulic drives into a machine design.
tive sensors have shown themselves to
be highly effective at delivering accurate
3
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Figures dont lie negatively impact how well your plant is run-
ning and the quality of products.
People dont like to advertise that this
line is a 42%, or this line is at 49%, said
Why you should be brutally honest Ken Bannister, a Toronto-area manufactur-
ing consultant who works with companies
about your OEE score. to improve maintenance practices and OEE
scores. They dont talk about it because
I
By Frederic Baudart ts a statistic. Its a useful benchmark. But someone is going to ask, Why are we so
Fluke Corp. overall equipment effectiveness (OEE) is bad and inefficient?
best used as a baseline for improvement, But its important for managers in manu-
not merely a bragging point to show how facturing, chemical processing, oil and gas,
well your manufacturing line, machine, or and other factories to know that while an
plant is running. OEE score is a key top-line metric to reveal
When managers initially calculate an OEE how well your operation is running at a given
score on individual production lines, they time, the score is just a data point fixed in
are often shocked at how low the OEE score time. Its a benchmark that can swing.
really is, and then they keep it quiet. How- To be sure, each manufacturing team
ever, production lines in the 30% range arent knows the critical equipment and process-
uncommon. es used to create products. Its that critical
An outgrowth of the Lean manufacturing equipmenttypically the most expensive to
movement, Seiichi Nakajima of the Japan replacethat draws the most attention and
Institute of Plant Maintenance (JIPM) first maintenance. But the OEE metric provides
described OEE in 1982 as part of the total a more holistic view of your operation, a
productive maintenance (TPM) methodol- way to monitor and improve efficiency in
ogy, according to the OEE Foundation. By the your manufacturing process by going beyond
mid-1990s, OEE had become a best practice simple uptime measurements.
Performance: By definition, performance is Different events within a plant should be assigned to different parts within the OEE
a percentage of the total parts produced by the calculation.
machine to the production rate of the machine. Or,
in other words, how well the machine is running If a company has a brand-new line specific downtime occurrences the line
when it is running. and its sister company has a line thats is experiencing. And if maintenance-
30 years old, and they both make the related downtime can be prevented or
Performance = Total Count / Target Count
same product, the OEE will truly be predicted that improves OEE.
Quality: Quality is a percentage of the parts pro- different, said Bannister You then Uptime of equipment is essential to
duced that meet specifications out of the total parts need to come up with some way of all industries. Unplanned shutdowns
produced on a machine or process. Simply put, how harmonizing them so its an apples- not only impact your OEE, but they
many good parts versus bad parts a machine or to-apples comparison. One way to do also can cost thousands of dollars in
process has produced. that is to look at specific problems and repair or replacement of critical equip-
Come join us on
May 10th - 13th, 2016 in Clearwater Beach, FL
info@uesystems.com
800-223-1325
Intl: +914-592-1220
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reventive maintenance (PM) should not be confused our key maintenance employees dont have other priorities.
with predictive maintenance (PdM), which is a series But the main reason companies fail at PM is because they
of dynamic inspections of machine components while havent included a profit motive: They havent incorporated
the machines are operating in their normal produc- a way to benchmark and track the savings that their PM
tion modes. program generates.
Heres what great preventive maintenance programs
should include: Reason 3:
Scheduled inspections and lubrication samplings that We didnt roll it out correctly.
determine the physical state of machine components Companies that fail quickest simply hand over PM imple-
The lubrications, adjustments, and documentation of mentation to their maintenance staff without the proper
needed repairs identified during inspections, which training and oversight/management.
prevent unnecessary wear and failure of machine com- Your companys biggest return on investment may come
ponents from an investment in consultants who can help you focus
Inspections and repairs during scheduled plant shut- your objectives, create PM tasks correctly the first time
downs when all machines are safely locked out, to ensure around, train your team, oversee all the implementation
safety and maximize production uptime. details, and ensure you are left with a management program
that will be effective. Make sure they have the hands-on,
If developing a PM program is such a no-brainer, why real-world experiences to ensure your PM programs suc-
doesnt every company have one in place? cess, and they dont simply leave the property after they
pile a ton of documents onto your desk.
Reason 1:
We didnt lay the groundwork/have the right systems. Reason 4:
Designing and implementing a PM program requires a very Our PM activities arent correctly weighted because we
different mindset than operating and managing a normal dont understand why breakdowns occur.
maintenance department. PM begins with understanding When PM task details are not written to address the root
your facilitys goals, setting performance standards for causes of breakdowns, you may be focusing on things that
equipment, documenting preventive maintenance pro- dont really impact productivity. If your company has a
cedures and schedules, and then uploading it all to your good work order system in place, measurements can easily
computerized maintenance management system (CMMS). be made using basic CMMS reports to measure the effec-
If the companys in-house experts can initiate and manage tiveness of your program over time.
these tasks, great. If not, find a qualified PM manager or To minimize unplanned machine downtime, a well-
contract with a capable PM consulting firm that can get designed PM program typically allocates 80% to 90% of
(and keep) the ball rolling. its time to machine component inspections and 10% to
20% to lubrications. PE
Reason 2:
Other things got in the way, and we never finished. Ken Staller has more than 30 years of project engineering,
Companies delay or stall their PM program for a variety of project management, and maintenance management experi-
reasons: A big order comes in, and its all hands on deck. ence in machine manufacturing, pulp and paper, pharma-
Raw materials are delayed, and we have to play catch-up ceutical, and automotive industries. Daniel Penn Associates
when they arrive. We cant seem to find a week when all is a CFE Media content partner.
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I
By Cindy Green ndustrial plants and facilities often buy Performance-requirement advantages
AutomationDirect machines and process skids for use in Focusing on performance requirements
their production, packaging, and logis- instead of specifying components allows
tics operations. As an owner, director, OEMs to stay in their comfort zone, pro-
or manager of a manufacturing plant, its viding benefits to the OEM and the pur-
important to purchase equipment that chaser. Perhaps the biggest advantage of
meets plant needs and can be easily inte- focusing on performance is more bidders
grated into existing production processes. will come to the party, giving purchas-
Many times, equipment purchases can get ers leverage in negotiations. OEMs know
bogged down in component details, instead their standard equipment and its capabili-
of focusing on performance requirements ties, so they can quickly ascertain if they
and specifications. Focusing on the perfor- meet the performance requirements. This
mance requirements affecting the machine will allow each OEM to provide a quota-
or process skid end product, and not the tion that clearly confirms conformance to
components running it, has advantages. the performance requirements.
This focus allows the original equipment Focusing on performance requirements
manufacturer (OEM) machine or process instead of component specifications also
skid builder to offer their lowest price, allows each bidder to build the equipment
shortest delivery time, and best support. the way they normally do, using their stan-
This confers a number of benefits to pur- dard components and designs. It allows
chasers. They include: them to use their standard pricing, which is
typically well-established and competitive.
More bidders By contrast, changes due to a purchas-
Lower cost ers detailed component specifications
Quicker lead time will force the OEM to develop a custom
Faster start-up quotation, which is often just an educated
More reliable operation guess with a fudge factor. Uncertainties are
Better support. created for the OEM by hardware changes
and required additional engineering and
Specifying performance requirements technician labor, inflating quoted prices,
such as machine cycle rate; process flow and lengthening lead times.
rates and pressures; output configurations; Providing detailed component specifi-
finished product specifications; environ- cations may require the OEM to redesign
mental, power, facility, safety, and dimen- the automation system and other major
sional requirements; and user interface assemblies. In the best case, the OEM will
requirements will go a long way toward have in-house resources available to do
realizing these benefits. this work, allowing them to price addi-
Understanding what to look for when it tions accurately.
comes to specifying, installing, integrat- Many OEMs wont have the required
ing, and maintaining OEM machines and in-house engineering resources available
process skidswith a particular focus on for custom designs. In this case, the OEM
automation systemscan improve every will typically hire a system integrator for
step of the process. control design and programming tasks,
and a mechanical engineering firm for Once a machine or process skid is pur-
mechanical changes. chased, it must be installed and commis-
For example, instead of just releasing sioned.
their standard drawings to build a control
or electrical panel, OEMs will send design Ease of installation and start-up
changes to an integrator. The integrator must E q u i p m e nt d e l i v e r e d b a s e d o n t h e
then provide a quote for the design changes OEMs standard design will result in
to the OEM, and a purchase order must be quicker installation and start-up. The
issued. Drawings also need to be updated OEMs technicians will be familiar with
and approved before parts can be ordered the automation system and other com-
and the panel built. In parallel, similar activ- ponents, instead of trying to figure out
ities may be taking place on the mechanical how the customer-specified components
side of the machine design. operate. Any required changes can be
Having tight, rigid specifications for com- performed quickly, as the OEMs com-
ponents will add cost and extend the sched- missioning and start-up personnel will
ule. Required additional design, approval, b e ver y fami li ar w it h t heir st and ard
and purchasing will add weeks if not months designs (Figure 1).
to the schedule. Not only will the chang- This is particularly true when it comes to
es extend the schedule, but risk will also the automation system. Specifying a par-
increase; as with major design changes, there ticular brand for an AC induction motor
is always the chance for rework, additional or a level switch might add cost and lead
changes, and related delays. time, but it will have minimal impact on
Handling integration
Meets Sustainability.
gration with existing plant automation
systems. This was a very serious issue
in the past, as many automation sup-
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Figure 3: Remote access allows most machine automation system and other issues should also specify compliance with
to be quickly resolved by the OEM from their home office, saving time and money the plants existing Ethernet protocol.
for both the OEM and the purchaser. Image courtesy: InduSoft Common protocols include Ether-
Net/IP, Modbus TCP/IP, and Profi-
net. All of these Ethernet protocols
provide the ability to transmit and
receive large amounts of discrete,
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and in the future for integrating
machines, process skids, and other
production equipment.
The last piece of the communication
puzzle is the communication schema,
which defines the language used when
different automation components talk
to each other. With the purchased
OEM equipment installed, integrated,
and started up, maintenance and sup-
port come to the forefront.
RAM-PRO-XL
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Although it may be more difficult for
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involved, which the plant should speci-
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Connectors
Squich spring-terminal, rectangular connectors offer
ease of use and cost savings on any harsh manufactur-
ing floor and rugged industrial environment by providing
quick-connect solutions for a variety of production machin-
ery. Each of the spring terminals has an actuator button
incorporated in the cavity. When this button is pressed
with a finger, it triggers the closure of the spring device of
the corresponding terminal, safely and reliably connecting
the conductor to its respective electric contact in the con-
nector. To reopen the terminals, simply insert the tip of a
common flat-blade screwdriver in the pocket on the actua-
tor; using a levering motion, gently press the screwdriver
downward. This will lift up the actuator back to the open
terminal position. The connectors are available in 6-, 10-,
16-, 24-, 32-, and 48-pole configurations.
Mencom Corp. Drive couplings
www.mencom.com SureMotion drive couplings are available in four styles:
Input #201 at www.plantengineering.com/information
jaw/spider, double-loop, Oldham, and beam-style
servo; bore reducers are also offered to fit a coupling
when the exact bore is not available. The SureMotion
jaw/spider coupling is a clamp-style coupling with 14
to 65 mm aluminum hubs and bore diameters ranging
from 4.7 to 32 mm. Polyurethane center spiders are
available in different durometers for different degrees
of shock and vibration reduction.
AutomationDirect
www.automationdirect.com/motion-control
Input #202 at www.plantengineering.com/information
Safety relay
The G9SE Safety Relay Unit is a slim-size safety relay
unit that significantly reduces installation and trouble-
shooting time/costs for machine builders. The units
screw-less, push-in terminal allows fast and easy
installation, and with one of the slimmest profiles on
the market it requires significantly less panel space.
The troubleshooting process is vastly simplified by
the design and usage of intuitive diagnostic LEDs. The
G9SE is ideal for a wide range of safety input devices,
such as emergency stop switches, door switches, and
light curtains.
Omron Corp.
www.omron247.com
Input #203 at www.plantengineering.com/information
Portable
magnetic drills
The power-feed HMD927
portable, magnetic drill
has the power to drill holes
up to 1-5/8 in. (41 mm)
in diameter. It offers great
power-to-weight ratio by
giving steel fabricators
Electromechanical
more strength and torque cylinder
while still maintaining the The second-generation EMC electro-
small, lightweight foot- mechanical cylinder features a hygienic
print. The drills LED pilot design and IP65 protection class. It is
light is built into the base suitable for applications with frequent
of the magnet and allows cleaning cycles in the food industry.
the operator to more effi- The new size EMC100-XC-2 increases
ciently and quickly line up the power density for feeding forces of
the pilot with the holes up to 56 kN, for applications in forming
center location in low-light technology. An optional force sensor
or no-light conditions. allows decentralized process controls
The drill is powered by a two-speed motor to maximize tool life and without a higher-level control system.
increase torque with larger-diameter cutters. Rexroth
Hougen www.boschrexroth.com/emc
www.hougen.com Input #205 at www.plantengineering.com/information
Input #204 at www.plantengineering.com/information
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84 January/February
Month 2014 P2016 LANT ENGINEERING
PLANT ENGINEERING www.plantengineering.com
PRODUCTMART
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Stay current
with technology
informed
Scale formation reduces the heat transfer rate and
and trends in increases the water pressure drop through the heat
electrical, exchanger and pipes. In fact, one study has shown
mechanical, that .002" fouling will increase pumping needs by 20%.
Remove at
rua
Line
ry/Feb
Janua
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A recent technology report issued
by Emerson Network Power, a divi- Technology is doing a very good job dealing
sion of Emerson, discussed four with the raw storage capacity of data, but tools
emerging models that will manage that allow someone to search, correlate, and
data centers around such issues as
access all of that data will be a critical element
computing capacity, sustainabil-
ity, and cyber security. According to turning all that data into useful information.
to Emerson, those four models are: Steve Hassell, Emerson Network Power
The Data Fortress: Taking a security-first HASSELL: When you look at BYOD and majority of
approach to data center design, deploying users, there are two different issues than users will still need some way to be able to
off-network data center pods for sensitive what you see with an internal hacker: the search for the data they need and will access
information. ability to directly load information, and it through what is called a direct query.
viruses or malware on the device. Techniques like master data management
The Cloud of Many Drops: The Emerson overlay a certain amount of structure across
report notes, Despite virtualization-driven The first issue revolves around both the an organizations data so that it can be found
improvements, too many servers remain intent of the BYOD user and the ability of through conventional tools.
underutilized. Some studies indicate serv- their device to remove information from the
ers use just 5% to 15% of their computing enterprise. The copies of this information CFE MEDIA: What are some circumstances
capacity. create a number of issues, especially from an that might lead a company to retain an
IP-protection and legal-compliance stand- on-site data center as opposed to using
Fog Computing: Introduced by Cisco, point. The most effective way to prevent this the cloud?
fog computing connects multiple small type of information leakage is by using some
networks into a single large network, with form of virtual client on the BYOD device HASSELL: There are a number of reasons why
application services distributed across to eliminate the accidental transfer of data a company may choose to retain some or all
smart devices and edge-computing systems and make purposeful removal more difficult. of its data on-site. Security and regulatory
to improve efficiency and concentrate data concerns are two reasons that are most often
processing closer to devices and networks. The second issue involves the spread of mal- cited, but application types or architectures
ware when an infected BYOD is connected and personal preference also play into the mix.
The Corporate Social-Responsibility- to the network. The use of a virtual client can
Compliant Data Center: The effort to help because you can allow complete access Its important to recognize that this isnt an
reduce carbon footprints Are pushing the to corporate information without allowing either-or discussion. Hybrid approaches
focus toward sustainability and corporate direct connectivity to the protected network. including owned, co-location, and cloud
responsibility. are increasingly popular and will probably
CFE MEDIA: Underutilized servers are one dominate for at least the near term.
Steve Hassell, president of data center issue. Underutilized data is another. How
solutions for Emerson Network Power, do you view the data-management issue CFE MEDIA: Whats your assessment of
discussed with CFE Media the report and in manufacturing, and how can cloud current data capacity? Are we keeping
its implications for manufacturing at a computing help? pace with the growth of data?
time when cloud computing and cyber
security are two of the most pressing top- HASSELL: There are two main sources of Hassell: From what I have read, there are
ics as manufacturers move into the era of underutilized data: access to the data and about 8 zettabytes (or 8 trillion gigabytes) of
the Industrial Internet of Things (IIoT): the ability to find the data. The cloud can help data today, and that number is expected to
the first issue by providing ubiquitous access grow to about 35 zettabytes by 2020. I think
CFE MEDIA: What are the security to data no matter where a user is located. that technology is doing a very good job
challenges of bring-your-own-device of dealing with the raw storage capacity of
(BYOD) users that are different from The second problem is much harder. While data, but having tools that allow someone to
deliberate attacks from hackers. How a lot of articles have been written about the search, correlate, and access all of that data
should manufacturers address this ability to use large, unstructured lakes will be a critical element to turning all that
BYOD security issue? of information (e.g., Big Data), the vast data into useful information. PE
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