Engineering Leaders Under 40

PlantEngineering.com

Emissions tackled
at Hyundai Steel
Also in this issue:
• Field test 3-phase squirrel cage motors
• Specify grab sampling systems
• Validate machines with virtual commissioning

and
Technology TM
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input #1 at www.plantengineering.com/information
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 SEPTEMBER 2020

SOLUTIONS
27 | Top 10 considerations for virtual QMS
audit success

30 | Wet electrostatic precipitators are

proven for emission control and gas
cleaning

34 | How to field test 3-phase squirrel

cage motors

38 | How to validate machines with virtual

commissioning

41 | Select and specify efficient, accurate

Cover image courtesy: Beltran grab sampling systems
Technologies

43 | PC control redefines intralogistics

Editor’s Insight distribution center efficiency
5 | Software still eating world
46 | Edge I/O brings more connectivity to
field devices and sensors
INSIGHTS 49 | Covid-19 accelerates digital
7 | Three reasons why businesses should transformation
invest in automation technology

10 | Will cobots replace people in

INNOVATIONS
manufacturing? 51 | New Products for Engineers

14 | Advanced capabilities are being

incorporated into EAM systems INSIDE: IIoT FOR ENGINEERS
3 | Turn SCADA data into greater
ENGINEERING LEADERS UNDER 40 profitability
17 | Younger workforce leads the way 5 | End users, OEMs and technology
for manufacturing partners engage on IIoT

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Technology TM
INSIGHTS
By Kevin Parker, Editor
Software still eating world
When Marc Andreesen
said that software is eat-
ing the world, he high-
lighted the shift from
a hardware-based to a
software-based econo-
my. Also, that software
is modeling the world
around us in an increas-
i n g l y c o mp r e h e n s i v e
way.
Not to mention that
software is a high-growth,
high-margin business.
Because running a software com-
pany is different than running a hard-
ware company is one reason why in
2018 Schneider Electric combined its
software assets with those of Aveva,
in which Schneider remains a major
stockholder.
In late August, Aveva agreed to
acquire OSIsoft for $5 billion. OSIsoft’s
PI system collects, normalizes, stores
and streams real-time, high-fidelity
operational data to applications, ana-
lytics and AI and ML platforms.
“PI is the leading data historian
platform for aggregation and visual-
ization of real-time data. It is an open
infrastructure to support best-of-breed
ecosystems and it is scalable from small
to midsize to the largest enterprises,”
Craig Hayman, CEO of Aveva, said in
a news conference held on Zoom.
At the same event, Dr. Pat Kennedy,
founder and head of OSIsoft, pointed
out that OSIsoft was, for a software
company, old. “OSIsoft was founded in
1980 while Microsoft started in 1978.”
The industrial sector was one of the
first to embrace the digital, but its use
today lacks the scale and scope found in
other sectors, such as retail or banking.
“It’s the decoupling of software and
hardware that will bring Aveva and
OSIsoft together. The architecture will
be edge, on-premise or cloud, depend-
ing on the use involved. Yes, there will
be distributed historians on drones,
drives and compressors, but there will
also be trillion-point systems,” Ken-
nedy said.
www.plantengineering.com PLANT ENGINEERING
Aveva is acquiring OSI-
soft for $5 billion. In the
press conference Hayman
said this included $4.4
billion cash and $600
million in Aveva stock
shares, making Kennedy
the largest individual
stockholder in the com-
pany, equivalent to about
4% of the enlarged com-
pany.
The sale will close by
year’s end. OSIsoft had been backed
by SoftBank, the Tokyo-based hold-
ing company that runs Vision Fund,
the world’s largest technology focused
venture capital fund, with more than
$100 billion in capital.
According to a recent piece in The
Washington Post, the fund and its
chairman, Masayoshi Son, have faced
mounting criticism, having lost $18 bil-
lion in 2019, including for big stakes
in Uber and WeWork. But OSIsoft is a
different matter. Son paid a little under
$1 billion for a 45% stake in 2017. The
fund will secure a 150% return on that
investment, given the $5 billion Aveva
is paying for OSIsoft.
OSIsoft’s 40 years of success comes
as a software provider native to the
industrial automation space, rather
than ones migrating from consumer
or other sectors. Many of the editors
who cover industrial automation have
known Pat Kennedy and his company
for most of those 40 years.
In fact, one editor remembers a time
during the dot-com boom of the 1990s
when Kennedy was not so inclined to
give up control of his company. One
prominent research analyst firm had
published a note saying that OSIsoft’s
revenues were at the point where it was
time to sell. (Companies with revenues
of $50 million or less at the time were
being bought up by larger automation
companies.) Kennedy waxed indignant.
“Who are they to tell me to sell my com-
pany?” he said.
Everything in its time. Everything
in its time. PE
Septemer 2020 • 5
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input #5 at www.plantengineering.com/information
INSIGHTS
DIGITAL TRANSFORMATION
By Gustavo Sepulveda
Three reasons why businesses should
invest in automation technology
Process automation is one of the most valuable additions a team can make in
terms of digital transformation
A
s information technology (IT) leaders
plan their upcoming fiscal year budgets,
there are many investments to consider.
However, it’s possible the most impor-
tant budget to consider is how to support its busi-
ness’ continuous digital transformation. Whether
that means investing in mobile devices for its
employees or replacing legacy machine infrastruc-
ture, committing to digital transformation is the
key to any company’s success. A specific area many
businesses are looking into for their warehouse and
plant operations is process automation technology,
including tools for predictive maintenance.
According to a 2019 Peerless Research Group
survey, there is an ongoing push to infuse more
ongoing software, automation and robotics into the
warehouse. Of the 32% of companies looking to
invest in these technologies over the next 12 months,
40% want more robotics and smart planning tech-
nologies. Automation is winning over businesses as
it has the potential to save hundreds of thousands
of dollars as errors and turnaround time decrease.
There are many potential routes a company can go
when choosing the right automation technology for
its worth, but predictive maintenance technologies
are a key place to start. While the benefits of pro-
cess automation vary, there are many reasons why
innovating and adapting technology is beneficial
to a company, including safety, quality assurance,
production efficiencies and more. Here are three
reasons why companies should invest in process
automation technology, including top advantages
such as having a deeper visibility into key technical
processes, an increase of operational reliability and
the ability to maximize the potential of resources.
1. Clear visibility into technical
processes
Organizations are continually looking for ways to
gain greater visibility into their operations to make
proactive, informed decisions. No matter the size of
a company, many are working with a blend of legacy
and modern infrastructure as key components to the
www.plantengineering.com
workflow. Automation technology is what weaves
together this infrastructure to make a cohesive and
agile system. To gain clear visibility into technical
operations, an organization must be prepared for
what’s to come. Key decision makers must always be
a few steps ahead of the game to execute a desired
task with precision. To do so, process automation
tools clear the path to efficiency with data-driven
solutions for operational accuracy. Implementing
process automation is one of the most valuable addi-
tions a team can make in terms of digital transfor-
mation as it offers wide visibility into operations,
which then leverages information for operational
reliability and efficiency.
2. Enhanced reliability for smooth
operations
Functional optimization of machines is key to meet-
ing customer expectations and delivering a quality
product. To optimize machinery, companies must
be able to predict when issues may occur. To detect
issues, however, companies need to make the shift
from reactive to proactive. Instead of correcting
an operational malfunction during or after it has
occurred, companies need to live in the preven-
tive and predictive mindset. With the assistance of
predictive maintenance tools, such as sensor tech-
nology and predictive software, operations can run
reliably by identifying issues before they happen.
Smart technology like this allows a smooth run-
ning and trustworthy operations with automation
to back up manual resources.
3. Maximizing the potential of
valued resources
The need for efficiency has never been greater as
companies deal with the confines of remote work.
When looking at efficiency, there are many driv-
ing factors and resources to consider such as exist-
ing tools and human capabilities. Companies need
to work with what they have, matched with new
automation investments, to perform the clean-
est of tasks at peak potential. Relying on process
PLANT ENGINEERING September 2020 • 7
 INSIGHTS
DIGITAL TRANSFORMATION
automation solu- to have key conversations on how to implement. The
tions not only benefits to having visibility in technical processes,
allows compa- an increase of operational reliability and maximizing
n i e s to b e tte r the potential of existing resources is vast and can
manage inven- save companies immensely on their bottom line.
tory with speed To prepare for making the investment, companies
a n d a c c u r a c y, must study their level of performance and identify
but also provides its key downfalls in its current workflow, includ-
the opportunity ing excess material and downtime. Once those gaps
to maximize all are identified and understood, a plan can be put in
resources without place on how to minimize machine downtime and
sacrificing qual- what exactly are the needs of the specific workflow.
ity. With confi- Once the problem is identified and the plan is laid
dence in smart out, it is then time to invest and reap the benefits of
automation tools, process automation. Whether companies are look-
performance ing toward artificial intelligence, Industry 4.0 or
Figure 1: The NPM- capabilities can increase drastically, all internet of things (IoT) technologies, smart tools
WX from Panasonic while saving on budgets and increasing for automation will greatly reduce costs and increase
is sophisticated return on investment (ROI). efficiencies for businesses across industries. The key
automated printed to success is to look at your workflow with a holistic
circuit board assembly Leveraging automation for view for seamless connectivity and productivity. PE
equipment. Image success
courtesy: Panasonic Once businesses understand the benefits Gustavo Sepulveda is process automation business head
North America of automation technology, they can begin at Panasonic North America.

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INSIGHTS
COLLABORATIVE ROBOTS
By Joe Schwartz
Will cobots replace people in
manufacturing?
The debate has been long — and shall continue — whether automation replaces
humans or increases productivity, quality and safety
A
rticles about automation in manufactur-
ing, particularly robotics and collabora-
tive robots, sometimes called “cobots,”
appear frequently in the press. The head-
line message often is focused on eliminating jobs
and replacing workers.
Every time I hear someone mention that automa-
tion is replacing people, I start to fidget as I prepare
for a debate. In Minnesota, we sometimes call this
the “yeah-buttal.”
We seem to have long forgotten that computers
with spreadsheet, word processing and presenta-
tion software have replaced slide-rules, calculators,
typewriters, transparency film and so on, as well as
stenographers and others who used these low-tech
tools. Thankfully. Of course, we use the computers,
10 • September 2020 PLANT ENGINEERING
and we are much more productive. The combination
of computer software and hardware might be consid-
ered a form of automation (as well as communication,
entertainment and a host of other functions), and
society has accepted this.
Manufacturing is different
The dynamic is different in manufacturing automa-
tion where there are still humans engaged in direct
labor on the factory floor — or at least on many
of them — and to the degree that automation may
enable the elimination of jobs, automation is some-
times viewed as a threat. We’ve all heard stories of
sabotage by disgruntled employees in automotive
plants and the like, although such instances were
likely overstated. The source of disgruntlement may
or may not have been the machine — it was just an
innocent victim in either case.
What is the purpose of automation? Is its goal to
replace people? Consider the data. According to the
Federal Reserve Economic Data (FRED), the U.S.
Industrial Production Index shows a continual rise in
industrial production since the 1920s, notwithstand-
ing the temporary recessionary blips in years such as
2009. Also, according to the Fed, U.S. manufacturing
employment peaked around 1979 at nearly 20 million
people, but since then has dropped to only a little
more than 12 million in 2017. Again, according to
FRED, production output per employee has literally
doubled since 1990.
The scenario portrayed above is clear: U.S. man-
ufacturers are producing more output with fewer
workers. Depending on your perspective, that may
not sound good. It may sound like a lot of unem-
ployed folks. However, if all those people simply
became unemployed, then the unemployment rate
Figure 1: A universal robot with Robotiq
gripper. A robot arm is faster, more precise
and usually stronger than a human arm, and is
programmed to do a specific, repetitive task
with little maintenance. All images courtesy:
Motion Industries
www.plantengineering.com
 should have risen accordingly, and dramatically.
Instead, the U.S. seasonally adjusted employment
rates of 6% to 8% in the late 1970s have dropped to
around 4% just prior to the recent COVID-19 period.
So, yes, automation (and other factors) have enabled
much higher levels of production output with fewer
people, and I readily admit that reducing labor costs
is indeed one of the goals.
Automation’s higher purpose
Ironically, however, in all my years of working in
the automation industry, I’ve rarely felt as if the sole
or even primary purpose of such investment was
to eliminate jobs. More often, the higher purpose
was to increase output, improve safety or improve
quality and precision. Consider a canning line run-
ning at 1,800 cans per minute. Only an automated
filling line could accomplish such a thing. Envision a
stamping press that, without proper controls, could
easily sever the operator’s hands or take a life. Think
about the sanitary and precision requirements of
medical device production or semiconductor fab-
rication. Many of these processes are only possible
with automation.
Most manufacturing firms, and even entire indus-
tries, today can exist only if they automate; and for
those of us in the automation industry, that gives us
a great sense of purpose. We help our customers do
what they do, make what they make, to stay in busi-
ness and often it is the only way they can continue
to operate here in the United States. By contrast, for
some time China was viewed as not being as highly
automated due to lower labor costs. But since 2013,
China has been the largest robot market in the world
due to all the reasons above — it’s not just about
reducing labor.
In the most general sense, automation is machin-
ery. Computerized numeric controls (CNCs) for
machining; packaging machines for food, beverage
or other consumer goods; conveyors for moving
product from one station to the next — just look
around at every object in sight that was manufactured
somewhere — your windows, your computer and
all its components, your eyeglasses, your flooring,
your credit cards, are possible due to some level of
automated machinery — even your car is a machine
that replaced a horse, and I don’t hear anyone com-
plaining about that.
Robots as poster child
However, a certain form of automation is frequently
the poster child for those who want to focus not on
the merits and necessity of automation, but on the
resulting efficiency and productivity from automa-
www.plantengineering.com
tion of manual processes, and elimination of jobs:
the robot.
Robots are not new. The earliest invention of what
could be considered a robot was by George Devol
of Louisville, KY, in the 1950s. He called the inven-
tion “Unimate,” short for “universal automation.”
It was considered “universal,” because, unlike most
machines that had a specific purpose, the Unimate
could be outfitted and programmed to do many
different jobs (although a far cry from truly “uni-
versal”). Devol was not successful commercially,
but Joseph Engleberger purchased the patent in the
1960s and ultimately succeeded in deploying many
robots under the brand “Unimation.” Since then, of
course, many other firms globally have launched
many other models, usually recognizable mostly due
to their brand’s prominent signature color — often
bright yellow, orange, blue or so on. These robots
have been used increasingly along with machinery
in all sorts of factories.
By the way, we’re focusing here on industrial robots,
those used in manufacturing, but we’re also seeing
robotic inventions in completely different contexts
such as in vacuuming your floor. That’s another
discussion entirely, although it’s probable that such
proliferation will drive a higher level of societal accep-
tance of the poor, beleaguered robot.
Why is the robot so often the target of such mis-
guided criticism? Well, it has arms. Actually, it typi-
cally has just one arm, and in the industry is even
sometimes simply called an “arm.” A robot arm is
faster, more precise and usually stronger than a
human arm (see Figure 1). It never gets tired, needs
a bathroom break or calls in sick. It is programmed
to do a specific, repetitive task, and typically requires
little maintenance.
Unfortunately, unlike a human, a robotic arm does
not have eyes, although certain television shows and
sci-fi movies did feature such human-like mechani-
cal creatures, with legs even. (By way of disclosure,
many robots do use vision guidance, although such
hardware doesn’t attempt to mimic the appearance
of a human, except for one misguided firm who actu-
ally marketed a robot with eyes on a display screen
— they even blinked.)
A real robot arm is typically fixed-mounted,
either on the floor or on a pedestal or table, and
programmed to follow a specific path — often quite
rapidly and with a lot of mass driven by powerful
servo motors, so you do not want to get in its way.
Sometimes, such as in welding applications, the arm
isn’t necessarily moving rapidly, but the operation
itself is hazardous, so one would not want to be too
close in these cases. For these and other reasons, the
PLANT ENGINEERING September 2020 • 11
INSIGHTS
COLLABORATIVE ROBOTS
Figure 2: View of a universal robot in a machine tending
application.
area in which the robot operates must be protected
from human access while it is operating, and there are
plenty of standards mandating this. Sometimes, the
guarding is like a cage around just the robot and its
operation, called a “robot cell.” Other times, as with
spot-welding robots on an automotive assembly line,
an entire area containing several robots working in
concert is guarded to keep people out, and the line
will cease to operate if a door to the area is opened,
or if a scanner detects something/someone in the
area that shouldn’t be there.
Enter, collaborative robots
Until this past decade, industrial robots were guard-
ed. But then came along the collaborative robot.
The essence of the term collaborative means that
it can collaborate or operate in collaboration with
humans. How can this be, and how is it not danger-
ous? The robot design is such that it is limited in
power and force, including a feature that stops the
robot instantly if a collision is detected, which can be
accomplished several different ways. In many appli-
cations, the robot can be deployed without guarding
12 • September 2020 PLANT ENGINEERING
it. A risk assessment always should be performed,
which still sometimes results in the application
being guarded, even though the robot is a “cobot.”
An example would be if the robot is moving a sharp
or protruding part that could cause injury, even with
the slightest collision.
The term collaborative also can have a secondary
meaning relating to the way it is trained. Rather
than purely by entering speed and coordinates via
a keyboard or pendant, they often may be trained
by moving from point A to point B with the human
hand, a nice collaboration of human and machine.
Although the ease of programming is not the primary
value proposition of a collaborative robot, it is often
a very compelling advantage that has helped to sell
many such arms.
Will cobots eliminate jobs?
Let’s return to the question of whether a collab-
orative robot can eliminate jobs and whether the
dynamic is different than any other form of auto-
mation. We’ve already indicated that direct labor
reduction is one of several goals of automation in
general, and the data shows increasing industrial
output over the years, while manufacturing employ-
ment has dropped in the same period. While I’m
certainly a proponent of automation in general, I
would posit that the collaborative robot is espe-
cially suited to reducing the number of people on
the factory floor in a one-by-one basis — remove a
person, replace with a robot. Why? If an employee
is performing a repetitive task for many hours a
day, it often is relatively easy to implement a col-
laborative robot in his or her place in a relatively
short time frame due to the ease of programming
and setup, and without all the guarding required
by traditional robots. For these same reasons, the
collaborative robot also is much more affordable
(not just the cost of the robot, but the installed cost,
which avoids much of the engineering time and
“robot cell” hardware) and therefore more easily
justified financially, so it simply follows that more
of them are likely to be deployed.
To be clear, we say it often is relatively easy to
deploy a cobot, but certainly there are many applica-
tions where deployment of any kind of automation is
challenging. Notable examples are where the product
being manufactured or processed is either difficult
to handle or is not very repeatable such as in cloth-
ing, where so much of its production has continued
to move around the globe in search of the absolute
lowest labor cost, or in meat processing, which (as
of this writing) is often in the news due to COVID-
19 outbreaks. The core reason for such outbreaks is
www.plantengineering.com
Figure 3: Another view of a universal robot in a 01– 03 December

2020
machine tending application.

the large number of workers, employed near each other

as they perform their butchering duties on an irregular
and complex “product.” There will likely be some success Düsseldorf, Germany
in increasing automation in these facilities — certainly,
the motivation is there, but to date, such achievements
have been elusive. WHERE DOES EVERYTHING
A final point about using collaborative robots to reduce
human labor — perhaps the best examples of successful REVOLVE AROUND
deployment are in production facilities where there are INDUSTRIAL VALVES?
multiple stations performing the same type of process such
as in a machining facility with multiple CNC machines. Only at VALVE WORLD EXPO.
Consider a facility with 30 CNC machines cranking out Visit the world’s leading trade fair
automotive components (see Figures 2 and 3). Without and experience the latest products,
robotics, you may need 20 employees to tend all the processes and technologies. With
machines (keeping a supply of blanks, placing the blanks over 700 exhibitors on more than
into the CNC and then pulling them out afterward). With 204,000 square feet, from December
cobots deployed on the CNCs, or at least most of them, 1 to 3, 2020. Connect with other experts
the operation may require only 5 to 10 operators — a at the VALVE WORLD EXPO FORUM.
meaningful reduction in labor — and as a bonus, a safer Learn about sustainability in the value
operation from the social distancing standpoint. chain through the new ecoMetals trail.

Looking ahead Find out more now at

It’s important to note that the employees mentioned above valveworldexpo.com
need to be more highly trained to operate collaboratively
with the robots, and just as important, it’s necessary to
employ or contract with someone who knows how to Entrance passes available online
program and install the robots. Fewer people are indeed starting in summer at
required, but they are generally better trained and more valveworldexpo.com/2130
highly compensated. Manufacturing is once again a great
place to build a career. What beautiful irony — reducing
labor expenses with more highly paid employees. PE
Sponsored by:

Joseph H. Schwartz is vice president group executive, Mi

Automation Solutions Group at Motion Industries. He has a
BSME from Purdue University and an MBA from Washington
University in St. Louis. Schwarz was CEO of BRAAS Company
input #8 at www.plantengineering.com/information
when Motion Industries acquired it in 2016.
For show information: Messe Düsseldorf North America
Tel. (312) 781-5180 _ info@mdna.com
www.mdna.com
PLANT ENGINEERING September 2020 • 13 For hotel and travel arrangements: TTI Travel, Inc.
Tel. (866) 674-3476 _ info@ttitravel.net
INSIGHTS
ENTERPRISE ASSET MANAGEMENT
By Megha Tatiya
Advanced capabilities are being
incorporated into EAM systems
Tools are meant to support actionable insights
A
sset management takes care of an asset
from the day it is installed to the day
it is decommissioned. In between, a
world-class enterprise asset manage-
ment system helps companies get the most out of
their resources. Fortunately, company assets are
smarter than ever before. As technology continues
its rapid evolution, organizations are using complex
digitalized assets to improve efficiency, output and
safety. As technologies become more advanced, the
systems that manage them need to keep pace.
Asset management tools
One important feature of today’s advanced asset
management is predictive maintenance. It can
prevent equipment breakdowns before they occur.
Maintenance is less disruptive than repair. Smart
assets and an integrated system can keep asset man-
agers one step ahead.
Technologies that are taking asset management to
the next level include the Internet of Things, geo-
spatial information systems, building information
modeling, intelligent Cloud, Big Data and artificial
intelligence. Each tool manages vast blocks of data
to provide actionable insights.
The Internet of Things (IoT): There was a time
when mobile telephones simply made and received
phone calls. Today, mobile users with an Internet
connection can close their garage door, check their
home security system or start their robot vacuum
from anywhere in the world. IoT is how connected
devices talk to one another. Using sensors and cloud
platforms, systems like Watson IoT and NordicId
allow physical assets to communicate information
about how they are performing. IoT-connected
assets share data in real time. This information
can help prevent maintenance issues or identify
opportunities to improve. IoT-based asset manage-
ment can increase efficiency, raise productivity,
automate maintenance, and predict future needs.
For example, Lufthansa puts IoT in action. The
airline uses an IoT strategy to mine data from its
14 • September 2020 PLANT ENGINEERING
maintenance, repair and overhaul operations and
make it available to customers. Real-time aircraft,
airport and weather sensor data optimize operations
and on-time performance. This focused real-time
strategy allows Lufthansa to consistently deliver an
exceptional customer experience.
Geospatial Information Systems (GIS): GIS is
like Google Maps for assets. It visualizes the spatial
relationships between assets, allowing companies to
make cost-effective decisions about where to spend
resources. GIS platforms like Maximo Spatial and
ArcGIS can help maintenance crews reduce travel
time by servicing assets near one another. GIS can
also identify hotspots of high-performing or low-
performing assets. This makes it especially valuable
to organizations such as public works, utilities, and
water treatment districts.
The Otay Water District in San Diego County, CA,
uses GIS to centralize data from multiple depart-
ments. The GIS visualizes topological, spatial, and
general relationships and captures how different
objects in the network interact with one another.
Building Information Modeling (BIM): BIM cre-
ates a digital representation of a built asset like
a facility or addition. It is particularly useful in
the architecture, engineering, and construction
fields. Platforms such as ModelStream and IBM
Maximo provide an end-to-end method for trans-
ferring information through the facility's design,
construction, and operational phases. This life-
cycle can take years and involve many stakeholders.
Without data management, information is often
lost in the move from one phase to the next. BIM is
a collaborative model that centralizes information
and makes it accessible to everyone throughout the
entire asset lifecycle. At Heathrow Airport, BIM
processes were implemented to maintain data and
create efficiency across asset lifecycles. The project
saved an estimated 3 to 7% in new infrastructure
costs. Hundreds of man hours were saved through
automation.
www.plantengineering.com
 Intelligent Cloud: Moving complex enterprise
asset management systems to the cloud can yield
solid savings for companies. Cloud-hosted systems
reduce the capital and operating expenses needed
to maintain systems. Platforms such as Microsoft
Azure and Amazon Web Services offer agility,
scalability, flexibility, and simplified governance
to lean organizations. This is an ideal solution for
asset-intensive organizations like manufacturing
and utilities.
IBM helped Sodexo, a company spread over
67 countries, to migrate 1.2 million assets to the
IBM Cloud. The flexible solution implemented
one production instance in the U.S. and one in the
E.U. More instances can be added anywhere in the
world. This allows Sodexo to efficiently manage its
data without the issue of clients having to access
resources overseas.
Big Data and Artificial Intelligence (AI): In the
IoT era, when everything from valves to vehicles is
connected by sensors and systems, there is an abun-
dance of data to be had. Big Data technologies can
be used to collect this influx of information, and AI
analyzes it to create actionable insights. Connected
assets generate more useful data than an old-school
analyst with an Excel spreadsheet could ever effec-
tively use. Platforms like Apache Hadoop, Oracle
Big Data Solutions, and SAP Predictive Analytics
standardize and process this complex information.
They can then generate insights that enhance effi-
ciency and maximize return on investment. BMW
implemented data mining in its German manufac-
turing plants to gain insight across a wide range
of warranty issues. The information gleaned from
this Big Data exercise was used to improve product
designs and modify service patterns. The result was
a five percent reduction in warranty cases, saving
the company more than $33 million a year.
To world-class management
The business world moves quickly, and competition
does not rest. Today’s customers have escalating
demands, including the expectation of 24/7 opera-
tions and rapid turnaround times. Global supply
chains and the rising cost of raw materials put addi-
tional pressure on companies.
If an entire line can be brought to its knees by a
single asset failure, the company is courting disaster.
Through predictive analysis, intelligent asset man-
agement can reduce or remove the risk of single-
point failures.
In addition, world-class asset management also
helps companies to run leaner. Predictive analyt-
www.plantengineering.com
Figure 1: EAM systems are incorporating technologies such
as IIoT of Things and intelligent Cloud and functionality
that includes building information modeling and geospatial
information systems. All figures courtesy: Megha Tatiya
ics can reduce downtime and lower repair costs.
Centralized data systems can lighten the admin-
istrative burden and cut through some of the red
tape between departments, allowing employees to
do their jobs more efficiently.
An outdated system may have gaps in data, unex-
pected asset failures, or stacks of information that
was collected but never used. Employees have likely
created a series of workarounds to get their jobs
done. Upgrading to a more efficient asset manage-
ment system will reduce waste while getting the
maximum benefit from every resource.
Implementing a new system
Implementing a new asset management system
is rarely as easy as flipping a switch. The change
takes time, effort and resources. But the long-term
advantages far outweigh the short-term costs. To
make the switch from a legacy system to a new,
digitized system, a cultural shift may be needed.
Employees need to understand exactly why the
system is changing and how it will benefit the com-
pany. People often resist leaving their comfort zone.
It is important that anyone who will be using the
new system receives adequate training. A company
that invests a great deal in a new tool but does not
train people to use it will not see the benefits of
the technology.
Implementation often requires a phased approach.
Operations are divided into silos and migrated into
the new system one at a time. In that way the new
system and legacy system are running concurrently.
Companies should take advantage of the oppor-
tunity to review the structure of their operations,
PLANT ENGINEERING September 2020 • 15
INSIGHTS
ENTERPRISE ASSET MANAGEMENT

Introducing new, smart assets requires reviewing

peripheral systems to make sure the new technol-
ogy has the support it needs. A new or refurbished
asset is a complex system capable of generating and
storing data. To optimize that asset, a company
needs the ability to use that data.
Information that is collected but never used adds
layers of needless complexity to business operations.
Modern assets are designed to optimize efficiency.
Using them to their full potential means having
systems in place that can analyze the data and a
workforce trained in using the data to make good
business decisions. PE

Megha Tatiya is an enterprise asset management (EAM)

Figure 2: The profile
of enterprise asset
management systems has
been raised due to their
relevance in efforts to
combat the Coronavirus.
including where is the company right
now and where it wants to be. Like
a chance to declutter the operation,
migrating to a new system is a prime
opportunity to improve processes and
eliminate redundancies.
and subject matter expert (SME) at the National Insti-
tute of Standards and Technology (NIST), where she
leads projects to analyze processes and propose solutions
for facilities-related IT systems. She has over a decade
of experience working as an EAM consultant and has
helped many multinational companies globally across
various industries to design, implement and maintain
world class EAM systems.

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input #9 at www.plantengineering.com/information
 C LASS OF 2020
Younger workforce leads
the way for manufacturing
Amanda Pelliccione, Project Manager
2020 has certainly been a challeng-
ing year, to say the least. The global
impact of COVID-19 on health and safe-
ty, the economy, education, manufactur-
ing and distribution – among many other
affected areas – is devastating, humbling
even. It is among these uncertain times
that Control Engineering and Plant Engi-
neering are incredibly honored to intro-
duce 34 manufacturing professionals
under the age of 40 who have and continue to make signifi-
cant contributions to their industries.
The Class of 2020 Engineering Leaders Under 40 is a
unique group of young individuals who jump at the chance
to solve a problem, however big or small. They are each
dedicated to their profession, driven by passions to learn,
tinker, design and make a positive impact on their commu-
nity and beyond. Asa Burke at Porex, for example, worked
Mohamed Abuali, 38
Managing Partner
IoTco LLC
Cincinnati, Ohio
BS Systems Engineering,
University of Arizona
MS Industrial Engineering, Ameri-
can University, Cairo, Egypt
PhD Industrial Engineering,
University of Cincinnati
In his 18 years of working in manufacturing, Mohamed has
learned extensively about plant connectivity, data acquisi-
tion, manufacturing execution, planning, predictive analytics
and artificial intelligence. His resume includes big company
names, such as IBM, Procter & Gamble (P&G) and Toyota,
and Mohamed has co-founded two companies, FORCAM
and IoTco, to serve manufacturers with the latest technolo-
gies and training for the Internet of Things (IoT)/manufac-
turing execution systems (MES), connectivity solutions and
a training academy to drive manufacturing productivity.
FUN FACT: Mohamed was 15 years old when he attend-
ed his first day of undergraduate school at the University of
Arizona.
www.controleng.com
day and night to develop for mass pro-
duction a porous, liquid/aerosol barri-
er for the pipette tips used in automated
testing equipment, which has been instru-
mental with COVID-19. Then there’s
Camila Jarrin, who works at Elite Spice
to prevent common food-borne illnesses
such as salmonella and E. coli.
Read about the contributions from
each of the Engineering Leaders Under
40, Class of 2020, in the following section and online at
www.controleng.com, and CFE Media and Technology
aims to honor these individuals at the annual Engineering
Awards in Manufacturing dinner in spring 2021, in down-
town Chicago (in-person event is tentative at this time).
• For information on how to nominate for 2021, visit:
www.controleng.com/EngineeringLeaders.
Jayashri Aja, 28
Customer Success
Manager
Rockwell Automation
Eagleville, Pa.
BS Industrial Engineering,
Pennsylvania State University
J
ayashri is a passionate lead-
er for female representation
and cultural diversity in automation and manufacturing.
She has lobbied in Washington, D.C., on behalf of Women
in Manufacturing, for which she is a local chapter chair, for
programs meant to provide opportunities for women to pur-
sue STEM careers. Jayashri was co-lead for Rockwell Auto-
mation Women in The Field, a prestigious position held for
2 years. She has mentored dozens of Rockwell Automation
employees helping them craft their unique leadership styles
and career paths.
FUN FACT: As an ASA 101-certified sailor, Jayashri loves
being able to pilot a vessel that relies entirely on renewable
energy sources and physics.
plant engineering September 2020 • 17
Oladeji Andrew, 23 Eric Angulo, 28
Manufacturing Technology Project Manager/
Project Engineer Automation Engineer
Niagara Bottling LLC Plus Groups
Diamond Bar, Calif. Cincinnati, Ohio
BS General Engineering, Harvey BS Chemical Engineering,
Mudd College Rensselaer Polytechnic Institute

W E
hile working on a
research project spon-
sored by Sandia Nation-
al Laboratories, Oladeji made an original contribution in
developing a centrifuge curing method to fabricate epoxy
composites with nanoparticles less than 200 nm in diameter.
Oladeji’s work with plastic materials fabrication has contin-
ued into his career at Niagara Bottling, where he specializes
in line management systems (LMS) integration, testing and
implementation. As a Lead Project Engineer, he is respon-
sible for an LMS-commissioning project at a 4-line plant in
Houston, as well as supporting many of the company’s 35
plants across the country.
FUN FACT: An avid baseball fan, Oladeji launched a daily
baseball podcast, Baseball Connection, and played Division
III baseball in college.
ric has successfully deliv-
ered solutions for multi-
national clients through
design, programming, construction oversight and startup
implementation spanning a variety of industries and sys-
tem platforms. His expertise ranges from designing and pro-
gramming complete facilities process automation system to
first in its industry OEM skid-based systems. Eric is client-
focused, detail-oriented and always working to provide his
customers, internal and external, the best overall solution
regardless of platform or product.
FUN FACT: Eric volunteers locally throughout the year to
assist his community with tasks such as delivering Christmas
presents to underprivileged children and distributing face
masks amid the COVID-19 pandemic.

Tiffany Barnes, 35 Ameet Bathiya, 31

Technical Solutions Plant Engineer
Consultant Protech Powder Coatings Inc.
Honeywell Strongsville, Ohio
Houston, Texas BS Mechanical Engineering, Mod-
BS Mechanical Engineering, ern College of Engineering, India
California State University at MS Mechanical Engineering,
Long Beach Cleveland State University

T A
iffany has quickly become a
key contributor to the glob-
al Technical Solution Consultant organization, which
provides Honeywell Sales and Operations organizations with
comprehensive and holistic technical and business exper-
tise for automation customers. She regularly interfaces one-
on-one with customers and has most recently focused her
expertise on the Life Sciences industry (Specialty Chemical
and Pharmaceutical processes) and batch processing solu-
tions. Tiffany often researches the regulatory needs of her
customers, speaks with regulators and other experts, and
actively seeks ways to incorporate solutions to these needs
into our products.
meet has played a vital role
in maintenance strategy
at Protech Powder Coatings by managing the company’s
preventive maintenance program and reducing annual main-
tenance costs by 25% in 2018 and by an additional 5% in 2019.
The program has reduced downtime, reduced energy costs,
increased production efficiencies from 67 to 75%, and reduced
material movement by 50%. Ameet has been working closely
with the Ohio EPA to obtain air permits and water discharge
permits to reduce pollutants released into the environment.
He also has implemented new safety devices and designed an
NFPA-compliant warehousing racking system to accommodate
more than 3,000 skids for storage.

FUN FACT: Prior to joining Honeywell, Tiffany applied her FUN FACT: Ameet’s interest in engineering stems from his
passions for science and problem solving as an engineer for father, and he began with touring local manufacturing com-
the Walt Disney Company. panies in the 6th grade.

18 • September 2020 plant engineering www.controleng.com

 ® ®

Mostafa Bayati, 32 Ron Brash, 31

Senior Controls Engineer Director of Cyber Security
Siemens Insights
Saint-Laurent, Québec, Canada Verve Industrial Protection
MS Mechatronics & Automation, Florissant, Mo.
University of Saskatchewan BS Technology, Security &

M
Network Administration, British
ostafa recently finished Columbia Institute of Technology
a project as SCADA lead MS Computer Science, Concordia
in a major Canadian air- University
port and is currently prepar-

ing to start a new challenge at Siemens as a Senior Controls
Engineer. As a young engineer, he has extensive knowledge
and experience in all aspects of control systems including
design, programming, commissioning and troubleshooting.
He is a lifelong learner and always stays current with the lat-
est technologies. Mostafa has published three textbooks and
several articles in international journals.
FUN FACT: Mostafa enjoys mentoring prospective engi-
neers and helping them to understand career opportunities
in automation and electrical engineering.
R
on is an experienced technology consultant and seasoned
cybersecurity specialist with deep expertise in critical sys-
tems, network security, deep packet inspection, IoT/cloud
dashboard, data analytics and secure embedded software
development. He leads Verve’s research on vulnerabilities,
cyber risk and firmware in OT/critical infrastructure. Ron’s
insights and analysis help inform the company’s technology
and product direction, and provide valuable guidance in client
engagements. His experience in the industrial industry has led
to his recent nomination as Vice President of the International
Society of Automation (ISA) Montreal, a nonprofit group set-
ting the standard for automation globally.

FUN FACT: Prior to pursuing a career in industrial cyberse-

curity, Ron was a professional wakeboarder.

Asa Burke, 27 Joe Carson, 33

Product Development Owner
Engineering Manager Pacific Blue Engineering
Porex Signal Hill, Calif.
Fairburn, Ga. BS Mechanical Engineering,
BS Mechanical Engineering, Ohio State University

I
Georgia Institute of Technology
n 2015, after working in the
automation industry for 5

A
sa has quickly risen with-
in Porex as top engineer-
ing talent, and in the 3 years since being hired, he has
been promoted three times and is now responsible for half
of the New Product Development department, managing the
hourly technicians and the salaried engineers on his team. In
2020, upon the onset of the COVID-19 pandemic, he urgent-
ly developed for mass production a porous, liquid/aerosol
barrier for the pipette tips used in automated testing equip-
ment. It was a fast-paced project that required a lot of late
nights, but he pushed through and was able to satisfy the
customer’s very strict requirements.
FUN FACT: Asa competes in volleyball tournaments around
the Southeast and volunteers his time to build houses in
impoverished communities.
years, Joe founded Pacific
Blue Engineering, a control sys-
tem integration company that provides turn-key automa-
tion solutions to Fortune 500 companies in seven industries.
Prior to 2015, Joe worked for Rockwell Automation running
the safety services business in the Pacific Southwest region.
He has earned TÜV Rheinland Functional Safety Engineer
certification and developed a company initiative to part-
ner with a local STEM student program to promote careers
in the math, science and automation industry for future
generations.
FUN FACT: Joe started his company without the help of a
partner or financial investor, building from the ground up in
just a few short years.

www.controleng.com plant engineering September 2020 • 19

Eric Chapman, 36
Engineering Director
Continuous Engineering
Solutions Inc. (Contensol)
Knoxville, Tenn.
BS Nuclear Engineering,
University of Tennessee
E
ric started his career work-
ing for the U.S. Navy’s
nuclear energy department building training programs
for battle-time field repairs of critical systems on submarines
and carrier ships. He also worked with Westinghouse on
critical Fukushima Nuclear Plant Safety Systems to upgrade
the fleets during meltdowns after lessons learned from Japan.
Later, Eric founded Contensol and aims to change the valve
and hardware industry with his inventions and patents. His
valve patent revolutionized valves for slurry applications and
elastomer valve automation. Eric’s contributions to powder
metallurgy with process patents completely change the way
fasteners are used and how they function.
FUN FACT: Eric has obtained five U.S. patents and founded
three industrial manufacturing companies in just 5 years.
Vince DiMascio, 28
Manufacturing Engineer
The Raymond Corporation
Greene, N.Y.
BS Mechanical Engineering,
Binghamton University
S O
ince joining The Raymond
Corporation 6 years ago
at the Greene, New York,
location, Vince has grown into a subject matter expert in
the capital projects process. Vince is an experienced project
manager who is able to deliver any size capital project and
has taken on a key leadership role not only within Greene’s
capital projects team but also within the larger manufactur-
ing engineering department. Vince is a technical mentor to
multiple engineers, and through helping them to develop
their skills at a more rapid rate, he’s helping set up the busi-
ness for long-term success.
FUN FACT: Vince often enjoys long hikes – recently tackled
Angels Landing and The Narrows at Zion National Park –
and is an avid, year-round fisherman.
20 • September 2020 plant engineering
Brendon Cordon, 31
Mechanical Engineer
Hine Automation
St. Petersburg, Fla.
BS Industrial Technology, Iowa
State University
A
t Hine Automation, Bren-
don has been recognized
several times through a
program that encourages team
members to identify when they feel a colleague has gone out
of their way to assist them in their daily tasks. He was once
recognized from the purchasing department for finding
replacement parts that normally had a very long lead time.
The company was scheduled to ship a product quickly and
had it not been for Brendon’s diligence, research and deter-
mination to find replacement parts solving the issue, the
shipment would not have made it on time. Brendon focuses
on integrations and system testing. Brendon also holds a Six
Sigma Lean Professional Certificate.
FUN FACT: Brendon designs and builds various projects in
his personal time with his own 3D printer, which includes an
expanded monitor stand and a custom keyboard.
Philip Fenimore, 25
Lead Automation Engineer
Panacea Technologies Inc.
East Greenbush, N.Y.
BS Electrical & Computer Engi-
neering, University of Rochester
ne of Philip’s first tasks at
Panacea involved video
graphic data recorders,
which he saw an opportunity to standardize the way clients
deploy, test and configure the data loggers and created an
entire process workflow from intake to deployment centered
around technology deployment. He created project tracking
tools from scratch and analyzed standard operating proce-
dures to look for ways to streamline deployment and usage
while maintaining clear work instructions for error proof
usage. Philip did this while training a team to execute proj-
ects on the technology, and he created an effective technol-
ogy team in the New York office.
FUN FACT: Philip is classically trained in piano and has
been actively playing for more than 10 years.
www.controleng.com
 ® ®

Will Healy III, 38 Justin Hudgens, 39

Industry Strategy Manager Engineering Manager
Balluff Worldwide Automationnth
Florence, Ky. LaVergne, Tenn.
BS Mechanical Engineering, BS Engineering Technology, Elec-
Purdue University tro-Mechanical Systems, Middle
Tennessee State University

W J
ill brings together the
unique combination of
engineering expertise
and marketing know-how. In his current role he develops
strategies to help customers and raise brand awareness. By
motivating cross-functional and global teams, Will active-
ly works to improve the customer experience. Additionally,
Will takes a hands-on approach to inspiring youth to explore
manufacturing careers and speaks regularly with enthusi-
asm on the topics of smart manufacturing and STEM. He
is an active member of multiple organizations, board mem-
ber of the Advanced Manufacturing Industry Partnership in
Cincinnati and works toward helping students gain the skills
needed for employment.
ustin provides techni-
cal leadership and proj-
ect management, and
guides and mentors Level I Controls Engineers at Automa-
tion NTH. Justin has been involved with all facets of controls
system integration including design, panel build, program-
ming, commissioning and debug, applications, project man-
agement and employee management. Under his leadership,
entry-level engineers quickly flourish personally and pro-
fessionally. Justin has worked on small to large automation
projects in a variety of market segments including life sci-
ences and automotive. Justin also plays an important role in
customer relationships, which are built on a foundation of
trust and confidence.

FUN FACT: Will is a proud father of three with a love/hate FUN FACT: Justin’s love of good food has earned him the
relationship with running – he’s participated in multiple half nickname “Lunch Box,” and he can always be counted on for
marathons and 5K races, plus one full marathon in 2012. grilling, smoking or other outdoor cooking opportunities.

Preston Hullen, 30 Davis Jacob, 24

Mechanical Design HSE, Quality, OPEX
Engineer Manager
Quality Transformer & Electronics Voith Paper
Milpitas, Calif. Springfield, Ore.
BS Mechanical Engineering, BS Chemical Engineering,
San Jose State University Oregon State University

P I
reston started at Qual-
ity Transformer & Elec-
tronics while pursuing his
bachelor’s degree at San Jose State University. He immedi-
ately contributed to design and documentation capabili-
ties, increasing AutoCAD offerings and using his skills to
improve product construction and provide thermal simula-
tions on electrical designs. He has spearheaded internal proj-
ects to develop new manufacturing systems and techniques
involving robotics and automation technologies. Preston has
also taken the lead on drawing up plans for construction and
layout of multiple buildings on a new manufacturing site, in
addition to other significant contributions.
FUN FACT: One of Preston’s latest hobbies includes flying
drones to obtain aerial footage of the company’s current and
upcoming manufacturing facilities.
n the short amount of time
that Davis has worked with
Voith Paper, he has shown
advanced abilities in project management, effective commu-
nication, analytical analysis and process improvement. He
effectively completed many projects and process improve-
ments affecting and improving all levels of the organization,
one of which included a solution to torque measurement and
torque tracking. Davis also has taken the initiative to evalu-
ate the needs and potential solutions, followed by purchasing
and implemented a more accurate, reliable and safer torque-
ing solution.
FUN FACT: In his spare time, Davis can be found at the
beach, camping with family and friends, or playing soccer or
ultimate Frisbee.

www.controleng.com plant engineering September 2020 • 21

Camila Jarrin, 26 Kevin Lord Josue, 25
Sterilization Engineer Field Services Engineer
Elite Spice Control Station Inc.
Jessup, Md. Manchester, Conn.
AS Arts & Science, Pasco- BS Electrical & Computer
Hernando Community College Engineering Technology, Pennsyl-
BS Chemical Engineering, vania State University

K
University of South Florida
evin joined Control Sta-

H
aving only been working
at Elite Spice for 3 years,
Camila has created and managed the thermal treatment
process for low moisture food products to be later used in
seasoning blends manufactured at the Jessup facility. She also
manages the internal documentation, regulatory guidelines
and inventory of all irradiated material for the entire compa-
ny. Camila works on ongoing validation work conducted at
Elite Spice on spices and other seasoning ingredients to pre-
vent food-borne illnesses such as salmonella and E. coli via
treatment processes.
tion in 2018 as an Associ-
ate Field Services Engineer.
In under a year, he was promoted to Field Services Engineer,
having contributed to numerous successful process diagnos-
tic and optimization initiatives. Since then, he has led proj-
ects at sites, including basic materials, food and beverage,
oil and gas and power and utilities. Kevin has contributed to
numerous internal and external publications. In 2019 he pro-
vided the core content for a technical report published by the
Electric Power Research Institute entitled: “Improving Unit
Startups to Reduce Cost and Improve Heat Rate.”

FUN FACT: Born in Ecuador, Camila emigrated to the U.S.
with her family at the age of 9. She was the first person in
her immediate family to obtain a bachelor’s degree and looks
forward to voting in her first election, as she became an
American citizen in 2019.
FUN FACT: Kevin possesses an ability to apply his engineer-
ing skills and artfully blend music that’s written in differ-
ent keys and characterized by distinct melodies, a hobby that
began in high school.

Brian Mathews, 36 Justin Modglin, 26

Engineering Manager Project Engineer
Scientific Dust Collectors Cresline Plastic Pipe Co. Inc.
Alsip, Ill. Henderson, Ky.
BS Engineering, Dordt College BS Mechanical Engineering,

B
University of Evansville
rian recently undertook

a special project at Scien-
tific Dust Collectors that
will advance product efficiency
and improve how the product is
viewed in the industry. On his own initiative, Brian read and
applied a related ASHRAE standard to design and build a
complicated test lab that conducts newly conceptualized tests
on dust collectors – a large effort that will have long-term
benefits for the company. Brian also has written and pub-
lished a technical book and numerous technical engineering
papers about various industry-related topics.
FUN FACT: Brian and his wife love to travel with their two
young children around the U.S. and compile special memory
books about the trips as family keepsakes.
S
ince beginning his career
at Cresline, Justin has
improved processes
throughout several facilities.
When new equipment is implemented, he looks for ways he
can take advantage of the new technology to improve exist-
ing processes. He is not afraid to try new avenues to show
his organization improvements in efficiencies, uptime, pro-
ductivity, quality and performance. Justin is responsible
for projects at six manufacturing facilities. Projects range
from design and replacement of equipment, to entire sys-
tems replacement. He also manages quality control for all six
locations.
FUN FACT: For his college senior project, Justin built a
rocket for a NASA-hosted student launch competition.

22 • September 2020 plant engineering www.controleng.com

 ® ®

Krista Novstrup, 38 Nojan Nowakhtar, 34

Manager of Analytics Controls & Energy
Engineering Engineer
Seeq Corp. Matern Professional
Seattle, Wash. Engineering Inc.
BS Chemical Engineering, Maitland, Fla.
University of Washington BS Mechanical Engineering,
PhD Chemical Engineering, University of Central Florida

N
Purdue University
ojan is responsible for the

U
pon graduating with her
doctorate, Krista was hired by ExxonMobil where she
managed a global team responsible for developing, deploy-
ing and supporting model validation software applications for
refineries. She established long-term technology development
and deployment plans, ensuring technical quality of applica-
tions, and consulting and implementation of a 5-year technol-
ogy deployment plan. Krista joined Seeq in 2018 as a senior
leader who has published multiple articles in the oil and gas sec-
tor, presented at industry events, and won enthusiastic support
based on presentations and customer engagements.
comprehensive design of
a complete controls retrofit at One Orlando Centre, a
20-story high-rise in downtown Orlando, where he developed
a custom sequence of operation that allows operation of a cen-
tral energy plant in the most efficient configuration based on
seasonal weather changes. He also worked on the development
of a controls system upgrade at Coleman Federal Prison, which
required forming a plan to execute extensive installation and
repair work in an active prison facility along with integration
between multiple building automation platforms to comply
with multiple energy conservation measures.

FUN FACT: Krista’s deliberate, thoughtful way of solving FUN FACT: Nojan is a fan of Formula One racing, with his
analytics challenges comes in handy when playing coopera- favorite team being Scuderia Ferrari. Recently, he complet-
tive board games and has earned her the nickname of “the ed the first level of Mercedes AMG Racing Academy at Road
professor” at Seeq. Atlanta racecourse.

William Phippen, 28 Brandon Purificacion, 31

Project Engineer Deputy Program Manager and
Parmalat Canada ILS Project Manager
Belleville, Ontario, Canada General Dynamics Mission Systems
BS Mechanical Engineering, San Jose, Calif.
Queen’s University BS Industrial & Systems Engineering,
MS Mechanical Engineering, University of Southern California
Royal Military College of Canada MS Engineering Management, Johns

W
Hopkins University
ill became the manager

of a remote engineer-
ing team while maintaining his responsibilities as a
process engineer for a manufacturing line, and developing
and launching two products to market. Somewhere between
the travel, his work and his home life he studied for his mas-
ter’s degree and his professional engineering designation. His
career trajectory towards the space industry was kicked off in
university where he was the captain of the space engineering
team. The team entered rover competitions and placed first
in Canada, second in North America and sixth worldwide.
FUN FACT: Will is a dedicated family man and an avid
hockey player, playing in games at least twice a week.
B
randon is currently work-
ing dual roles at GDMS as a Deputy Program Manager
and an Integrated Logistics Support Project Manag-
er. Over the past 10 years, he has worked for three of the
top six defense contracting companies in the world. Bran-
don’s efforts for workplace efficiency were acknowledged by
Northrop Grumman Mission Systems, which presented him
with the Honor Roll of Inventors Award for automating and
improving the company’s timecard processing and reporting.
This process enhancement provides accurate time recording
that helps the company with future proposal bids and correct
billing to the U.S. Navy.
FUN FACT: Brandon enjoys the physical challenge of obsta-
cle course races, such as Tough Mudder and Spartan Races.

www.controleng.com plant engineering September 2020 • 23

Eric Reisz, 33 Josh Ruiz, 35
Lead Engineer/Project Maintenance Manager,
Manager Instrument & Electrical
Panacea Technologies Inc. Dow Chemical
Montgomeryville, Pa. Freeport, Texas
BS Chemical Engineering, BS Electrical Engineering, Texas
Widener University A&M

E
MBA, University of Houston
ric observed that within the

life science industry is an
inability to connect third-
party pieces of equipment into a cohesive and standardized
data model. He gathered client feedback, spoke with SMEs,
and helped craft the framework for a new product that puts
disparate data systems into a single stream harnessing the
Industrial Internet of Things. At Panacea, Eric helped devel-
op standards for a skills tracking software that helps sharp-
en the engineering skills of their team and provides training
opportunities for engineers to better their skill-sets and push
their career forward.
FUN FACT: In his spare time, Eric moves away from engi-
neering and into the world of art – oil painting and playing
the drums.
J
osh has received more than
10 awards from NASA for
his projects and eight Dow Chemical awards for his
contributions. He is involved with his local chapter of the
International Society of Automation, where he is a frequent
presenter. Josh created the Instrumentation & Electrical Reli-
ability Program that has enabled Dow to increase reliability
by 10% year over year. With this program, Josh has propelled
Dow Chemical with innovation in distributed control sys-
tems and process instrumentation. Josh customized software
programs to read over 10,000 HART instruments continu-
ously from a central location, optimizing costs and reducing
unplanned events.
FUN FACT: Two years ago, Josh built a remote-control
lawnmower with a camera attached, allowing him to mow
his lawn without breaking a sweat.

Matt Shewan, 37 Raj Subramanya, 35

Technical Manager Engineering Manager
Chemtrade Logistics Hine Automation
North Vancouver, British Columbia, Canada St. Petersburg, Fla.
BS Mechanical Engineering, Queens University BS Mechanical Engineering,

I
University of South Florida
n his 10 years with Chemtrade Logistics, Matt has demon-

strated technical expertise in many areas of the manufac-
turing process along with exceptional leadership skills. In
his current role, he manages an annual capital plan of $10 to
$15 million, and he provides technical/operational support
to the plant as well as technical guidance within the com-
pany on pipe and materials specifications. Matt led a group
of engineers and plant employees in major troubleshooting,
plant operations and debottlenecking improvements, includ-
ing effluent treatment, brine treatment operation and waste
chlorine neutralization operations.
FUN FACT: Matt enjoys camping, hiking, skiing, golfing
and introducing new sports to his two young boys.
• See more details in images and profiles at
www.plantengineering.com/EngineeringLeaders
B
eyond developing signifi-
cant leadership skills in
the engineering field, and
being extremely adept in gen-
eral machine design, Raj has invested a great deal of time
and energy working with maskless microlithography, atomic
layer deposition, rapid thermal processing, chemical vapor
dispositioning, and plasma enhanced vapor dispositioning.
Raj has been with Hine Automation for 5 years and serves as
a key leader on the team. His leadership style allows his team
to explore solutions and prove their knowledge through real-
world experience, while providing a safety net of help.
FUN FACT: Raj has a passion for mountain biking and
hiking; the highest he has climbed so far is 11,700 ft in
Colorado.

24 • September 2020 plant engineering www.controleng.com

 ® ®

Keyi Sun, 34 Donald Van Raalte, 38

Director of Industrial AI Division Manager
and Lighthouse Academy Interstates
Foxconn Industrial Internet Sioux Center, Iowa
Milwaukee, Wis. BS Computer Science, Information
PhD Chemical Engineering, Systems & System Administration,
North Carolina State University Dordt University

K D
eyi leads the training and
development of Foxconn
Industrial Internet’s “Lights-Out Factory,” which has
been selected among the World Economic Forum Global
Lighthouse Network, a community of state-of-the-art facili-
ties that serve as world leaders in Industry 4.0 manufactur-
ing. She also founded the Fii Lighthouse Academy to provide
industrial artificial intelligence training to Foxconn employ-
ees. In addition, she established Lighthouse Academy’s “data
foundry,” which provides real-world industrial Big Data to
train engineers with practical analytics skills.
onald is the Division Man-
ager of the software develop-
ment group at Interstates. His team plays a critical role
in automating projects as clients often have custom manu-
facturing execution systems or software requirements that
he and his team build solutions for to connect the controls
layer to the enterprise resource planning layer. Donald has
played a key role in Interstates’ transition to an agile devel-
opment methodology, leveraging agile scrum and Kanban on
projects. This has led to efficiency gains and increased client
involvement throughout the projects.

FUN FACT: Keyi volunteers with One-School, where she is FUN FACT: Donald enjoys hobby software development on
part of a small team of teachers who educate underprivileged single-board computers to automate household activities like
children in rural areas. running sprinklers and security monitoring.

Sandeep Kumar Raju Zheng Yi, 29

Vysyaraju, 29 Senior Control System
I&C Project Engineering Engineer
Manager Suez North America
Samsung Austin Paramus, N.J.
Semiconductor LLC MS Electrical Engineering,
Austin, Texas Stevens Institute of Technology
BS Electronics & Instrumentation,

Z
GITAM University
heng is highly motivated
MS Electrical & Control Systems,
Oklahoma State University
and experienced in proj-
ect management, data analytics and visualization, design
and development of process automation, SCADA and con-

S
andeep has been instrumental in implementing (and
bringing the industry he works for to) the standards that
are key to success. He worked in several brown field and
green field projects related to instrumentation and controls
and has upgraded several retrofit and archive projects that
helped in saving costs and improve the efficiency of systems.
Sandeep volunteers with the International Society of Auto-
mation, helping run the divisions and participating in sev-
eral panel discussions held at symposia to share knowledge
about industry standards related to automation.
FUN FACT: Sandeep has mentored and prepared several
school teams to participate in robotics competitions.
trol system architecture. He has introduced and facilitat-
ed convergence of Suez IT and OT, and the development of
an enterprise SCADA data center. The Smart SCADA sys-
tem he designed transforms traditional operation. For plant
operators, the Smart SCADA embedded distribution sys-
tem automation program removes the burden of managing
small tasks and allows them to focus on the mission-critical
objective: consistently providing safe, quality water to the
community.
FUN FACT: Zheng loves to explore new technologies and
thrilling sports, such as skydiving, snowboarding and scuba
diving.

www.controleng.com plant engineering September 2020 • 25

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input #10 at www.plantengineering.com/information
SOLUTIONS
QUALITY MANAGEMENT SYSTEM AUDITS
By Alisa Coffey and Rich Mintz

Top 10 considerations for virtual

QMS audit success
Manufacturing can’t wait; consider these 10 recommendations for a successful virtual
quality management system audit

I
n a time when many have switched to remote recertifications. Depending on audit type and certifying
working and all of us hopefully practice social agency, it may or may not be an ideal solution for your
distancing, the COVID-19 pandemic challenges company based on timing, circumstances and your audit-
workforces. It seems improbable during this time ing team’s capabilities. In the instance of a surveillance
that manufacturing companies could obtain certification audit, a preexisting relationship with your certifying body
for their quality management systems in what would (established in an initial certification) will help the auditor
traditionally be done in an onsite certification process. prepare questions. A surveillance audit would prove to
However, a manufacturing business must stay commit- be more appropriate for a virtual auditing process than
ted to the quality and safety of its products and prove an initial certification or recertification.
itself resilient amidst market and economic challenges.
For Abaco Systems Inc., whose surveillance audit 2. Plan the audit
was scheduled at the height of COVID-19 concerns, Adopting a clear agenda with internal and external teams
Figure 1: A transitioning to a virtual audit to remain up to date will help set expectations, scope, process, technology
virtual audit on its AS9100 certification was of the utmost impor- needs and other parameters. This will prove vital in
is a great tance. AS9100 is an extension of ISO9001 certification staying organized, making sure all necessary parties
compromise with additional requirements for quality management are included in each discussion and establishing a well-
when neither systems for the aviation, space and defense industries. paced plan for completing the auditing process.
safety nor Abaco worked with TÜV SÜD Americas, its certify-
quality can be ing agency, to accomplish the necessary changes in the 3. Be tech savvy
compromised. auditing process. These changes included starting each Tech prowess is king — tech troubles or failure may
All images day with a virtual kickoff, then a series of breakouts come across as unpreparedness if the team is not ready
courtesy: with an Abaco leader managing a virtual meeting with to use the technology in place for the audit. Strong tele-
Abaco the auditor and concluding with a virtual closing meet- communication skills as an organization are necessary
Systems Inc. ing. After adapting to meet the changes required by for a seamless process. Abaco routinely uses telecom-
COVID-19, Abaco con- munication software (Skype, GoToMeeting and other
tinued its strong tradi- platforms), but if an organization is weak in teleworking,
tion of receiving full it may prove ineffective — or worse.
recognition to operate
as an AS9100 certified 4. Be in tune
company (see Figure 1). Your plant has a rhythm with set schedules, shifts, batch-
In retrospect, here es and the like. In a face-to-face audit, the auditors can
are 10 things to con- watch employees or come back later if it is not an ideal
sider so that your orga- time. With a virtual audit, the agenda may be far more
nization can excel in a rigid and “coming back later” won’t work.
virtual audit.
5. Be visual
1. Discuss audit To bring live visuals into the audit, Abaco had the ability
options to submit pictures to show compliance in response to
Different kinds of audits questions asked by auditors. The same would be possible
have varied purposes: with video footage. Advance work and planning to use
initial certifications, prepared charts, pictures, videos and other visual aids
surveillance audits and that have already been prepared is ideal for a virtual

www.plantengineering.com PLANT ENGINEERING September 2020 • 27

SOLUTIONS
QUALITY MANAGEMENT SYSTEM AUDITS
8. Be thorough
A virtual audit needs increased planning in advance, and
part of that planning occurs through having a clear path
for information retrieval. When an auditor is waiting
across the table, it can be intimidating, but we found the
process to be less stressful when those being interviewed
have files clearly organized in such a manner that data is
easily accessible when questions are asked. The overall
nature of a virtual audit has a stronger focus on the
written process and depends more heavily on having
well-documented records for evidence.

9. Be ready
Figure 2: audit but may require some leg work on the front-end Perhaps there is a misconception that a virtual audit is
Abaco during preparation (see Figure 2). an easier option, but if anything, the exact opposite is
Systems’ Ben true. A virtual audit requires far more extensive plan-
Branham, 6. Be secure ning and preparation for both the organization and the
global quality In a face-to-face audit, the auditors can observe and make certifying agency. The auditor will be equipped with
director, notes, but proprietary information is not recorded or pre- questions for those they will interview, and are armed
demonstrates served in an electronic format. Many companies have rules with prior knowledge of your organization’s processes,
that strong against taking photos or videos on the plant floor, but these strengths and weaknesses. They will know when to ask
teleworking rules become a challenge or obstacle to overcome in the questions and press further with inquiries to be sure
prowess and face of a virtual audit. It’s imperative to obtain the necessary that the processes in place are effective in maintaining
the inclusion permissions in advance of the audit by explaining the neces- standards that meet the requirements for certification.
of visual sity, how and where they will be shared or stored, who will Despite a variance in format, the process is equally, if
materials is have access and for how long. An existing nondisclosure not more, rigorous.
essential for a agreement may or may not cover this situation between
virtual audit. the organization and the certifying body. 10. Be yourself
As with any audit, your quality team and the certifying
7. Be safe agency’s auditing team have the same goal in mind:
Manufacturing safety is achieved through rigorous proof that your quality management system is a living,
processes and continual situational awareness. It is breathing and working system. This provides the oppor-
important to note that fragile environments can be bet- tunity to show evidence of continuous improvement on
ter served by a virtual audit because they cause fewer action items with tangible results. This is accomplished
interruptions on the warehouse floor. However, when through clear communication, extensive planning and
an auditor is videoconfer- an excellent relationship between the organization and
encing into a plant, routines the certifying agency.
may be off and there can be a
loss of situational awareness Final thoughts
that would otherwise remain Abaco worked extensively with TÜV SÜD to adapt
intact. Each person involved to a changing environment while taking pride in its
must take precautions to pay accomplishments, specifically in the strength and inno-
attention and stay on task vation of the team. Mark Alpert, vice president of busi-
so that safety is maintained ness assurance at TÜV SÜD Americas, said, “We are
throughout the audit (see proud to recognize Abaco’s AS9100 Certification. This
Figure 3). achievement demonstrates Abaco’s unwavering com-
mitment to its employees, customers and quality. TÜV
Figure 3: Factors SÜD America shares these values and moved quickly
outside the norm, to ensure its audit services could be delivered remotely
like extra personal in a way that put the safety of both organizations first,
protective equipment while not sacrificing quality or service.” PE
(PPE) and virtual audits,
throw off routines and Alisa Coffey is the head of marketing at Abaco Sys-
could create potential tems Inc. in Huntsville, Ala. Rich Mintz is a product
hazards. marketing manager at Abaco Systems Inc.

28 • September 2020 PLANT ENGINEERING www.plantengineering.com

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input #11 at www.plantengineering.com/information

idt-hid-plant-engineering-ad-en.indd 1 9/2/20 5:54 PM

SOLUTIONS
EMISSIONS CONTROL
By Gary Siegel
Wet electrostatic precipitators
are proven for emission
control and gas cleaning
Two case studies illustrate the point
I
ndustrial plant engineers have a wide variety of
pollution control and gas cleaning systems from
which to choose. Regardless of the manufac-
turing process, from automotive production to
zinc smelter operations, wet electrostatic precipitators
(WESPs) have proven particularly valuable in indus-
tries that emit sulfur oxides and sulfuric acid, such
as metallurgical smelters and refineries; petroleum
refineries; fossil-fuel power plants and industrial boil-
ers; and municipal waste incinerators.
WESPs are also valuable in the manufacturing of
electronic components such as semiconductors, printed
circuit boards and microchips. Potential air emissions
from these industries include doping agents; hazardous
gases; organic solvent vapors; particulates; and sulfuric,
hydrochloric, and other acids. For controlling particu-
late emissions, and condensed organic compounds,
WESPs remain the technology of choice.
Another forward-looking technology, biomass gas-
ification, requires high-efficiency cleaning of syngas
30 • September 2020 PLANT ENGINEERING
produced from the thermochemical conversion of car-
bonaceous wastes. Then, for maximum energy produc-
tion (via synfuel engines, gas turbines or liquid fuel
combustion), the gas must be purified to extremely
high standards. All these plants are impacted by emis-
sions control and gas cleaning problems.
What’s available
Systems and equipment available to plant engineers
include wet and dry flue-gas scrubbers, cyclones,
fabric filters, thermal oxidizers and dry electro-
static precipitators. These types of systems can be
cost-effective in controlling large-scale particulates,
oxides of sulfur and nitrogen and other hazardous air
pollutants. However, they are usually inefficient or
ineffective on such problematic industrial contami-
nants as fine particulates, acid mists, heavy metals
or condensed organic compounds. In these cases,
engineers continue to rely on modern versions of
a technology that has been used for years to reduce
dust and fumes from industrial exhaust and process
gases: the wet electrostatic precipitator.
The basic WESP design makes use of an array of
negative discharge electrodes surrounded by grounded
collection surfaces. Source gas is passed through the
array, which induces a negative charge in even the
most minute, submicron-size particles, impelling them
toward the collection surfaces. There they adhere as the
cleaned gas is passed through. The captured particle
residues are purged from the plates by recirculating
water sprays.
The simple elegance of the basic WESP design
concept makes it versatile over a broad range of
industries, applications, operating conditions, loca-
tions and gas chemistries. Still, it is important for
At Mopani Copper Mines in Zambia, nine
electrostatic precipitators are used for sulfuric
acid gas cleaning. All images courtesy: Beltran
Technologies.
www.plantengineering.com
 engineers to recognize that there are key differ-
ences in features and benefits among the various
precipitator systems. WESPs can vary greatly in
design, materials, gas flow rates and durability, as
well as collection efficiency.
Subtle differences
Today’s advanced WESPs are designed around a multi-
stage system of ionizing rods bristling with star-shaped
discharge points, enclosed within various collector
tube shapes, such as round, space-saving square or
hexagonal tubes. This unique electrode geometry gen-
erates a corona field 4-5 times more intense than that
of other electrostatic precipitator designs, resulting
in greater particle migration velocity and collection
efficiency. Fine particulates and aerosols, which have
little significant mass and easily escape through ven-
turi and other scrubbers, are captured at up to 99.9%
efficiency with a well-designed WESP.
Wet electrostatic precipitators can process a wide
range of gas streams. They are often used downstream
from wet or dry flue gas desulfurization units, which
cannot capture fine particulates and acid aerosols.
They are also superior when applied to high ash con-
tent and sticky residues (which may also contain mer-
cury and heavy metals), oily residues/tars, mercury
(as condensed oxide) and emissions from municipal
solid waste (MSW) in waste-to-energy plant applica-
tions, as well as others.
Compared to WESPs the challenge for traditional
dry precipitator designs is the possible re-entrainment
back into the gas stream of particles from the collec-
tion surfaces. Dry-operating ESPs, especially those
using mechanical, acoustical or vibrating rapper
methods, are particularly susceptible to this phenom-
enon. Precipitators based on wet operation, however,
minimize re-entrainment, as the aqueous flushing is
operating continuously. The elimination of these rap-
ping methods also reduces the higher cost and energy
requirement imposed by that equipment.
Because the WESP processes gases in a cooler, satu-
rated environment — usually between 100° - 170°
F — it is uniquely adept at capturing condensable
organic materials and acid mists, such as found in
sulfuric acid plants like Mopani Copper.
Mopani Copper case history
Mopani Copper Mines Plc, a unit of Glencore Xstrata
based in Switzerland, operates sulfuric acid production
facilities at their copper smelter plants in Mufulira and
Kitwe in Zambia. The sulfuric acid plants currently
have nine wet electrostatic precipitators designed and
engineered by Beltran Technologies for sulfuric acid
gas cleaning.
www.plantengineering.com
At Hyundai Steel in South Korea, twin wet electrostatic
precipitators remove submicron particulate and visible emissions
from exhaust gas.
Industrial-grade sulfuric acid, still the most widely
used industrial chemical in the world, continues to be
sourced primarily as a nondiscretionary byproduct
from the roasting, smelting and refining of nonferrous
metals (70%), and from natural gas processing, electric
power generation and spent acid regeneration. These
industries are usually heavy emitters of particulates,
sulfur and nitrogen oxide gases, and sulfuric acid
mists, among other pollutants. They are also subject
to increasingly strict environmental regulations.
When concentrations of sulfur dioxide from these
operations exceed 5-7% of exhaust-gas volumes, a
common and cost-effective solution is the incorpo-
ration of a downstream sulfuric acid manufacturing
plant. Owners of these facilities can capitalize on the
high industrial market value of purified sulfuric acid,
while achieving greater operating efficiencies.
An efficient sulfuric acid manufacturing process
requires the maximum possible removal from input
gas streams of fine particulates, acid mists, condens-
able organic compounds and other contaminants. This
high level of gas-cleaning efficiency is necessary to
prevent poisoning of the catalysts and fouling or plug-
ging of the catalyst beds. An optically pure input gas
is essential for avoiding the formation of a “black” or
contaminated acid end-product.
Hyundai Steel case history
In the recent past, Hyundai Steel, Seoul, South Korea
purchased Hanbo Steel Co. Hanbo Steel had operated
PLANT ENGINEERING September 2020 • 31
SOLUTIONS
EMISSIONS CONTROL

the steel plant for some time using a Japanese horizon-
tal wet electrostatic precipitator that was inefficiently
removing particulate matter. After Hyundai bought the
steel plant, it revamped most of the air pollution control
equipment to comply with the country’s regulations.
The Hyundai Group has the reputation of being a lead-
ing company in Korea. And they wanted to eliminate
emission problems.
Hyundai manufactures steel for cars, buses,
trucks and high-speed trains. They use a scarfing
process, i.e., a thermochemical exothermic reaction
of oxygen and fuel which reacts with and removes
surface defects from cast steel.
The reaction of oxygen with the steel results in
a high concentration emission of submicron iron
oxide particulate difficult to remove by ordinary
methods. The scarfing process produces a peak
emission of submicron particulate in a concentra-
tion of 2500 mg/Sm 3. The Korean Environmental
Agency requires an outlet concentration not to
exceed 5 mg/Nm 3. This requires the WESP to have
a high-performance efficiency of 99.8% and the
process has a high of volume 4,000 Am 3/min. The
scarfing process produces a great deal of particu-
late and visible emission. Hyundai Steel quenches
the exhaust gas using water spray in a 100-meter
length tunnel. Gases then go to the wet electrostatic
precipitators to remove the submicron particulate
and visible emission.
For an exhaust gas volume of 4,000 Am 3/min,
Beltran Technologies designed two WESPs oper-
ating concurrently. Beltran guaranteed 99.8% at
an inlet condition of 2500 mg/Sm 3 and an out-
let concentration of 5 mg/Sm 3. However, Beltran
achieved more than 99.8% in the WESP operation.
Beltran attained under 1 mg/Sm 3 during the WESP
operation which is a more than 99.96% submicron
particulate reduction.
For steel mills, sulfuric acid plant production,
metallurgical/mining operations and so many other
industrial applications, the WESP has a long history
of achievement reducing fine particulate aerosols
and visible emissions. PE
Gary Siegel is marketing director, Beltran Tech-
nologies, Inc.

IoT For Condition Based Maintenance

In the last decade, we’ve seen a rapid increase of IoT-enabled solutions into the industrial
world. Traditionally, machine condition monitoring has relied as much on an employee
as on technology. However, better and cheaper sensors, broader connectivity, more
sophisticated analytics, less expensive storage and multi-cloud technology is eliminating
the need to perform manual time-based tests to monitor your machine’s health. The IoT is
automating and adding intelligence to machine condition monitoring and allows more time
for operational optimization.

By connecting equipment, organizations can capture massive volumes of data from sensors and other
connected devices, so they can not only cut unplanned downtime and its associated costs, but also create
new operational efficiencies, exploit new opportunities in supply chain optimization, and accelerate their
overall digital transformation strategies.

Register to download the paper at:

www.descase.com/resources/iot-for-condition-based-maintenance/

communications@descase.com • 615.672.8800 • www.descase.com

input #12 at www.plantengineering.com/information

pe202009_whitePprHlf_descase.indd 1 8/31/2020 9:02:31 AM
 Engineering is personal.
So is the way you use information.
CFE Media delivers a world of knowledge to you.
CFE Media is home to some of the Personally.
most trusted names in the business.

www.controleng.com www.csemag.com www.plantengineering.com

MAY 2017
Inside:
 Technologies and
technicians p8
 The signal processing
perspective p12

Supplement to Periodicals Publication

IFE1705_MAG_Cover_V2msFINAL.indd 1 4/26/17 4:35 PM

SOLUTIONS
MOTOR TESTING
By Thomas H. Bishop, P.E.
How to field test 3-phase squirrel
cage motors
Maintenance of critical machines depends on the diagnostic electrical testing of
installed 3-phase squirrel cage motors, interpretation of results and key points of
physical inspection
E
fficient, reliable operation of critical elec-
tric motors is top of mind for maintenance
professionals tasked with keeping produc-
tion at optimum levels while avoiding cost-
ly, unexpected shutdowns. Besides routine mainte-
nance, this requires that critical motors be inspected
and tested regularly. The focus of this article is on
diagnostic electrical testing of installed 3-phase
squirrel cage motors, interpretation of results and
key points of physical inspection. Most of these tests
and inspections also apply to 3-phase wound rotor
motors and induction and synchronous generators.
Table 1: Recommend minimum insulation resistance values at 40°
C (all values in megohms)
Minimum insulation
Test specimen
resistance
IR1min = kV + 1 For most windings made before about 1970, all
field windings and others not described below.
IR1min = 100 For most ac windings built after about 1970
(form-wound coils).
IR1min = 5 For most machines with random-wound stator
coils and form-wound coils rated below 1 kV and
dc armatures.
Notes:
1. IR1min is the recommended insulation resistance, in megohms, at 40° C
of the entire machine winding (all phases).
2. kV is the rated line-to-line voltage for 3-phase ac machines, line-to-
ground voltage for single-phase machines, and rated direct voltage for
dc machines or field windings.
3. It may not be possible to obtain the above minimum IR1min values for
stator windings having extremely large end arm surface areas, or for
dc armature windings with commutators. For such windings trending
of historical IR1min values can be used to help evaluate the condition of
their insulation.
4. The values (in the above table) may not be applicable, in some cases,
specifically when the complete winding overhang is treated with stress
control material.
5. The values in the above table do not apply to “green” windings before
global vacuum impregnation treatment.
Reference: IEEE Std. 43, Table 3.
34 • September 2020 PLANT ENGINEERING
Inspection and testing
Besides visual inspection, offline condition assess-
ment and diagnostic tests for 3-phase squirrel cage
motors typically include insulation resistance (IR)
and polarization index (PI) or dielectric absorp-
tion ratio (DAR) tests. Depending on operating
conditions and availability of test equipment,
offline testing and inspection also may include
lead-to-lead resistance and surge tests, sampling
lubricating oil for analysis and checking for soft-
foot, output shaft runout and alignment of motor
to driven equipment.
Inspection. The scope of the visual inspection
will vary with the motor enclosure type. If the
motor’s interior is not accessible (e.g., no remov-
able covers), carefully inspect its external surfaces
for wear, cracks and broken or missing hardware.
Items to check include the frame, feet, terminal
box, fan covers, cooling fans and the output shaft
and coupling or other shaft-mounted components.
If the motor’s interior is accessible, it may be
possible to inspect the windings and other internal
components for defects or damage, including the
air gap between the rotor and the stator (see Figure
1). A borescope and mirrors on extension rods
can probe recessed areas like the rotor’s interior
and the space between the stator core and frame
to check for debris, contamination, blocked ven-
tilation ducts, cracked welds or a loose fit of the
rotor core to the shaft.
Record all damage and defects, remove debris
and contamination and perform any maintenance
or repairs that need immediate attention. If neces-
sary, schedule nonessential maintenance or repairs
for the next regular shutdown.
Insulation resistance tests. The IR test is a well-
defined method of evaluating the ground insula-
tion of all types of motor windings (see Figure
www.plantengineering.com
 2). It consists of applying the test voltage and Table 2: Examples of how line voltage variation affects
measuring the winding’s resistance to ground after temperature and efficiency.
one minute. IR readings are temperature sensitive,
Minus 10% Normal Plus 10%
so to be meaningful they should be corrected to Voltage / (414 V) (460 V) (506 V)
the standard temperature of 40° C (see Table 1). Full load
PI is an extension of the IR test and is calcu- hp (kW) Temp. Eff. Temp. Eff. Temp. Eff.
lated by dividing the IR reading at 10 minutes by
megohm value at one minute. The recommended 10 (7.5) 66° C 90.0% 56° C 91.4% 55° C 91.5%
minimum PI value for windings rated Class B 20 (15) 84° C 90.4% 70° C 91.8% 67° C 92.1%
(130° C) and higher is 2.0, and 1.5 for Class A
50 (37.5) 84° C 91.9% 69° C 93.1% 62° C 93.6%
(105° C) windings. Windings with a lower PI
value usually are unsuitable for service. If the IR 100 (75) 82° C 94.2% 72° C 94.8% 69° C 94.9%
value is greater than 5,000 megohms, per IEEE 200 (150) 90° C 94.9% 77° C 95.5% 74° C 95.7%
Std. 43 and IEC Std. 60034-27-4, the PI value
would not be meaningful, and the PI test need coupling during one revolution. NEMA Standard
not be performed. MG 1 (NEMA Std. MG 1) allows up to 0.003-inch
The PI test is most useful with stator form coil (0.08 millimeter) total indicated runout (TIR) for
windings (coils made with rectangular or square shaft diameters of 1.625 inch to 6.500 inches (41
wire). It may not be meaningful for random- to 165 millimeters). A more rigorous yet simpler
wound windings (coils made with round wire) criteria is to limit runout to no more than 0.001
because the winding absorption charging current inch (0.025 millimeter) for 2-pole motors, 0.002 Figure 1:
decays within the first minute or so of applied inch (0.051 millimeter) for 4-pole motors and Stator coil
voltage. For those windings, the DAR is more 0.003 inch (0.076 millimeter) for motors with six damaged by
useful, with a common selection of IR readings or more poles. short-circuit or
taken at 30 seconds and 60 seconds per IEC Std. inrush current.
60034-27-4. Online motor testing All images
Online (running) tests vary by machine type (e.g., courtesy:
Lead-to-lead resistance test. By comparing the squirrel cage induction, synchronous, wound rotor). EASA
phases or circuits in the winding, the lead-to-lead If the motor can oper-
resistance test can detect high resistance joints ate safely, these may
in winding and lead connections. Per CSA C392 include me asur ing
and ANSI/EASA AR100, the resistance unbalance the starting (inrush)
limit for random windings should be 2% from current, line-to-line
the average, and 1% from the average for form voltages and voltage
coil windings. unbalance. On large
motors or those pow-
Surge test. The surge test can detect turn-to- ered by variable-fre-
turn, coil-to-coil or phase-to-phase shorts. A quency drives (VFDs),
common issue when surge testing an assembled it also is important to
motor is “rotor coupling” — a magnetic interac- check for shaft cur-
tion between a squirrel cage rotor and the stator rents.
winding that can produce a dual trace of volt-
age as seen on the screen of a surge tester or an Inr u s h c u r r e nt
oscilloscope. Turning the rotor a few mechanical test. Strictly speak-
degrees will merge the traces, unless the wind- i ng , i n r u s h i s t h e
ing has a fault or other defect (e.g., unbalanced asymmetrical dc
winding circuits). Perform the surge test only if offset that occurs in
the winding has an acceptable IR value and, if the first cycle, or a
applicable, an acceptable PI value. few cycles, after an

Shaft runout test. Mechanical tests include Figure 2: Insulation

the output shaft runout test, which uses a dial resistance test
indicator to measure shaft displacement at the of motor stator
end of the shaft (if possible) or adjacent to the windings.

www.plantengineering.com PLANT ENGINEERING September 2020 • 35

SOLUTIONS
MOTOR TESTING

a c motor is e ne r- derating horsepower by 12%. Since this often is

gized (see Figure 3). impractical, many motors end up operating on
According to NEMA unbalanced voltages with reduced output torque
Std. MG 1, the inrush and increased current. The higher current is espe-
current can be 1.8 to cially significant because NEMA Std. MG 1 says
2.8 times the locked- current unbalance with load can be six to 10 times
rotor current, which the percent voltage unbalance. Applying this rule
is t y pi c a l ly s i x to to the 3% voltage unbalance, the current unbalance
eight times the full- could be 18% to 30%.
load current. Conse- Heating is a function of the power loss in a
Figure 3: quently, it could be as much as 22 (2.8 x 8) times winding; specifically, the current squared times
Asymmetrical the full-load current. For a motor with a higher the resistance (I2R). With 3% voltage unbalance,
offset of than typical locked-rotor current, it can be high the highest current “leg” of the winding may have
electric motor enough to trip circuit breakers. When taking about 18% more heating due to the associated cur-
inrush current. measurements, unless the ammeter can measure rent unbalance. The additional heating is estimated
momentary inrush (peak) current, it will only by calculating twice the voltage unbalance squared,
indicate the steady-state, locked-rotor current. in this case:

Line-to-line voltages test. Line-to-line voltages 2 x 3 2 = 18%

should be within 10% of the motor’s rated volt-
age, according to NEMA Std. MG 1 and within A thermal scan of the windings, if accessible, can
5 % p e r I E C Std. record the actual temperatures resulting from unbal-
60034-1 (10% for anced voltage and current conditions.
l i m i t e d d u r at i o n Infrared thermographic scanning of a motor’s
and f re quenc y of exterior also can indicate areas of abnormal heat-
o c c u r re n c e ) . To o ing (see Figure 5). While there are no specific tem-
high a voltage can perature standards for the outer surface (“skin”)
increase heating of of electric motors, comparing a motor’s surface
the motor's magnetic temperature with identical ratings under the same
core, while too low or similar load conditions may reveal abnormal
a voltage can reduce heating.
its torque capability
(see Table 2). There Shaft currents tests. Large motors and motors
is no rule-of-thumb supplied by variable-frequency drives (VFDs)
to estimate whether should be checked for shaft currents (see Figure
over voltage will 6), even if none are suspected. In large motors,
increase or decrease for example, magnetic circuit dissymmetry due to
the motor current, segmented laminations can induce shaft currents.
and likewise with Likewise, VFDs may link the rotor and stator by
Figure 4: the under-voltage. capacitive coupling, creating circulating “shaft”
Derating currents that can cause premature bearing failure.
for voltage Unbalanced voltage test. Another factor relat-
unbalance per ed to voltage is unbalanced voltage. According to Figure 5: A motor driving a blower. Normal
NEMA Std. NEMA Std. MG 1, a motor should be de-rated if image on the left, thermal image on the right.
MG 1. voltage unbalance exceeds
1% — a requirement often
confused with the toler-
ance for voltage variation
(see Figure 4). Utilities
frequently limit the volt-
a ge u nb a l an c e for t h e
power they supply to 3%,
which, according to NEMA
Std. MG 1, would require

36 • September 2020 PLANT ENGINEERING www.plantengineering.com

 Field testing is necessary to detect bearing currents shaft exceeds 300
from VFDs and some other causes. Measuring the millivolts ac.
current directly is not practical in this case, as it would
require wrapping a current transformer around the Final thoughts
shaft inside the motor — i.e., between bearings. The Field test ing and
alternative is to measure the voltage from the frame inspection of motors
to the shaft to determine if it is enough to indicate is an important part
damaging shaft currents. of maintaining
A way to measure shaft voltage in the field is to essential and often
attach one lead of a true root-mean-squared (RMS) critical machines.
voltmeter to the frame (a grease fitting is a good Taking time to learn
location) and the other to the shaft using a brush-like ab out t he prop er
device (e.g., a fine copper wire such as a brush shunt) tests and procedures,
to drag the shaft and sense the voltage. Directly and how to apply
sensing the voltage from the shaft with a meter lead them, will allow you
is not recommended because it typically will not to improve reliability
maintain continuous contact. and reduce costs. PE
If the sensed voltage exceeds 100 millivolts ac Figure 6: Shaft
for rolling bearings or 200 millivolts ac for sleeve Thomas Bishop is a senior technical support spe- current paths
bearings, damaging shaft currents are probably cialist at EASA Inc., St. Louis. EASA, a CFE Media through an
present. Another criterion from NEMA Std. MG content partner, is an international trade associa- electric motor.
1 says damaging shaft currents may exist if the tion of more than 1,800 firms in about 70 countries
measured voltage between opposite ends of the that sell and service electromechanical apparatus.

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SOLUTIONS
DIGITAL TWINS
By Bill Davis
How to validate machines with
virtual commissioning
Virtual commissioning begins with a vision of the desired machine behavior and
sequence of operation
I
ndustrial machinery end users want customized
products delivered quickly. Meeting this demand
requires machine designs to be sophisticated.
This need for high-level customization with
greater machine complexity drives manufacturers to
support a global machine design to implement manu-
facturing strategies. Manufacturers can enhance their
machine validating process with virtual commission-
ing, thus meeting complex customer demands quickly,
efficiently and cost-effectively. This process builds on
innovative trends to create superior customer service
and revenue streams with new business models.
Virtual commissioning definition
Virtual machine simulation and commissioning is
the process of validating the software code for pro-
grammable logic controllers (PLCs), human-machine
Figure 1: Using virtual commissioning in conjunction with a
digital twin can create outstanding efficiency on the shop floor
by reducing time spent on physical validation, verification and
commissioning. All images courtesy: Siemens Digital Industries
Software
38 • September 2020 PLANT ENGINEERING
interfaces (HMI) and supervisory control and data
acquisition (SCADA) equipment in the virtual world
before deploying it on the factory floor.
As software is driving machines, its complexity is
increasing significantly. It is essential to simulate the
code running on a machine's virtual twin to generate
substantial dividends in time and resources. Virtual
commissioning validates the PLC software in a man-
aged environment, an integral part of the modular
product development strategy. Machine builders can
perform the simulation upfront and link the software
to the modules, combining the final code seamlessly
on an individual customer-specific machine.
Financially, virtual commissioning and visualiza-
tion pay enormous dividends for companies. No one
purchases a machine sight unseen. Also, they will not
buy it merely because it has been virtually simulated
by running software code. Therefore, users need to
substantiate that a machine works before shipping it
to their plant.
However, because many software integrations and
safety factors are necessary to run a machine, it is critical
to test it with users physically present. Hence, virtual
commissioning is ideal for turning a machine on and
performing real commissioning. There is less pressure
for both the machine builder and its customers/users.
It collaborates the engineering upfront in the design
process to further reinforce the interdependency of
all the disciplines involved in virtual commissioning.
Virtual commissioning essentials
Critical elements of the virtual commissioning pro-
cess include:
Upfront automation linked to machine behavior:
Virtual commissioning begins with a vision of the
desired machine behavior and sequence of operation.
Ideally, a systems model would define the machine
behavior in electrical and fluids domains. A physics-
based kinematic model is a good beginning by intro-
ducing forces on sliding or rotating components at
different times, providing a good visualization tool
www.plantengineering.com
 to communicate between the mechanical, electrical
and controls engineers. It’s also an excellent tool for
demonstrating machine behavior to users.
The behavior model drives code generation: The
machine behavior model (a physical demonstration
of the machine operation sequence) identifies the
logical devices in the design attributes critical to the
PLC and HMI code development. Consider a motor
with an integral encoder. The visual behavior model
describes a process where the motor is energized for a
certain number of rotations, stops and then reverses.
The PLC code must know essential information about
the motor/encoder and the expectations for use in
the application. Possessing vital information in the
mechatronic model provides for managing it more
efficiently.
Closed-loop feedback visualization: The upfront
simulation of the desired machine behavior is only
valuable when validated after the finished code loads
into a virtual PLC, showing machine operation in the
digital twin when driven by the code, not the predic-
tive machine behavior model.
User experience implementation: The user experi-
ence is vital to the virtual commissioning process. It
shows how the digital twin demonstrates the machine’s
response to user-initiated commands — for exam-
ple, indicating that the operating parameters display
appropriately on the HMI and whether the touch-
screen and other interface devices operate correctly.
Also, the virtual machine must respond correctly
during an e-stop or normal shutdown and simulate
faults and other use cases where safety is a concern.
Benefits and challenges
The demand for virtual commissioning, in conjunc-
tion with the digital twin, provides the following
advantages:
• Compressing time: Caters to users who are con-
tinually changing their tastes quickly and driving
a reciprocal need to respond rapidly.
• Saving costs: Reduces time to debug the design
and its associated controls physically.
• Minimizing risk: Provides virtual testing, so evo-
lutions present theoretical issues, with no PLC
program problems.
Virtual commissioning benefits create efficiency
on the shop floor, achieving higher speeds with reli-
ability — a potential 20% improvement in the capacity
of a machine shop or operations. This efficiency saves
valuable time previously spent in physical validation,
verification and commissioning (see Figure 1).
However, the upside of innovative technologies
come with their accompanying challenges:
www.plantengineering.com
• Validating third-party equipment integration
requires the need to bring disparate systems and
code together cohesively.
• Robotic integrations require connecting robotic
code into the PLC to increase efficiency.
• Logistics automation provides significant profi-
ciency only by orchestrating multiple interfaces
simultaneously.
Many use cases tout the benefits of virtual commis-
sioning. Consider two companies who are witnessing
notable improvements.
Successfully using virtual commissioning
Tronrud Engineering is a prime example of effec-
tively using virtual commissioning. Tronrud develops,
manufactures and supplies innovative machines and
equipment to users. Using a new machine’s digital twin
allows the designers, engineers and programmers to
work simultaneously while continuously sharing their
knowledge (see Figure 2). This process significantly
compresses commissioning and engineering time.
“By working on the design, mechanical compo-
nents and programming simultaneously, we can dras-
tically reduce the time to market. In another project,
this approach allowed us to save about 20% or two
months,” said Erik Hjertaas, general manager packag-
ing technology at Tronrud Engineering.
In response to the parallel execution of develop-
ment steps in an interdisciplinary team, Tor Morten
Stadum, PLM manager at Tronrud Engineering, said,
“We shortened the design phase by about 10% and
commissioning by 20% to 25%.”
Eisenmann, a Germany-based global provider
of industrial solutions, plans and builds made-to-
measure manufacturing, assembly and enterprises
throughout the world. They have deployed highly flex-
ible distribution plants that are energy- and resource-
efficient for more than 65 years. They’re reaping the
many benefits of virtual modeling, simulation and
commissioning.
“The simulation model we create with plant simula-
tion is often part of the deliverable to our customers.
Many of them also use plant simulation themselves,
so they know how to run the simulation and change
the needed parameters. This is a big benefit for them
because they get a virtual model of the physical line,”
said Dr. Heiner Träuble, simulation expert, automotive
paint systems, Eisenmann.
“We are very pleased with the discrete event simu-
lation capabilities we have developed in Eisenmann
throughout the years, especially our use of plant simu-
lation,” said Sebastiano Sardo, senior vice president,
Eisenmann Conveyor Systems.
PLANT ENGINEERING September 2020 • 39
SOLUTIONS
DIGITAL TWINS

Adapting machines for the future turers create a comprehensive digital twin. It also
Manufacturers must consider current trends and integrates simulation within the machine design
adapt to changing consumer preferences to build to be flexible, capable and adaptable. Connected
flexible machines that address a full range of prod- machines, which can communicate with other
ucts. Flexibility must be built into the machine machines, extend their capabilities through soft-
software to respond to the changing needs of the ware-driven changes. This value is essential for
customers. modern manufacturers to maximize the productiv-
Using the Xcelerator portfolio, a suite of services ity of the end-user environment.
Figure 2: from Siemens Digital Industries helps manufac- Companies need a digital solution that crosses all
Tronrud aspects of a machine manufacturer’s product and pro-
Engineering duction process to connect, adapt, predict and extend
is effectively the machines of tomorrow, today. PE
using virtual
commissioning Bill Davis is the solution director for the industrial
to align machinery and heavy equipment industry for Siemens
multiple Digital Industries Software. His experience and insights
processes have been acquired from a career spanning 30 years in
and shorten engineering and operations management with machin-
overall ery and heavy equipment companies. He has a master’s
commissioning degree in business administration from Marquette Uni-
and versity, with a concentration in operations management
engineering and strategic marketing, as well as a BSME from Mil-
time. waukee School of Engineering.

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SOLUTIONS
QUALITY ASSURANCE
By Matt Dixon
Select and specify efficient,
accurate grab sampling systems
How fluid vessel types and other variables influence system design
G
rab sampling plays a key role in many
refineries and processing plants around
the world, helping operators maintain
quality control, regulatory compliance
and assurance that products are up to specification.
The process is performed by capturing a sample in an
appropriate container, then transporting the sample
to a remote laboratory for analysis.
Samples must remain representative of process con-
ditions from the point of capture through analysis to
ensure accuracy. Yet, certain grab sampling system
design choices can highly influence sample integrity
and therefore the accuracy of readings. This article
will review some practical tips to help grab sampling
technicians maintain accuracy, including important
considerations for system designs and sampling ves-
sel choices.
Specifying systems
Grab sampling system design-
ers must first consider the
type of vessel to be used for
sample transport. The choice
is typically between a glass or
polyethylene bottle, or a sealed
metal cylinder.
A few factors determine this
choice. Bottles cannot contain
pressure, for example, and can
only be used for liquid sam-
1a: Front 1a: Back ples. By contrast, cylinders can
1b 1c
www.plantengineering.com
Table 1: Grab Sampling System
Recommendations for Common System Criteria
Container Type
Captured Phase Pressure- Non-Pressure-
Containing Containing
Liquid ✓ Cylinder ✓ Cylinder
X Bottle ✓ Bottle
Vapor ✓ Cylinder ✓ Cylinder
X Bottle X Bottle
✓ = recommended
X = not recommended
maintain pressure and are appropriate for liquid or gas
samples. See Table 1 for a quick reference.
Other important design considerations include:
• System Pressure. Grab sampling systems have a
maximum pressure rating – and it is important
that designers do not exceed that pressure for safe
operation. For chemicals that may rapidly expand
and pressurize under temperature changes, con-
sider using a rupture disc or relief valve.
• Temperature. Systems also have a maximum tem-
perature rating. Exceeding that rating can damage
seats and seals in the system. Importantly, sys-
tems also have a minimum operating temperature,
which helps ensure the fluid flows at a sufficient
rate for timely analysis.
• Material Compatibility. A process fluid and the
grab sampling system itself must be compatible
with each other, or else corrosion issues can occur.
Figure 1: This design is for sampling a gas
without a separate purge line (1a). With the
sampling system valves and the cylinder valves
open (1b), process fluid flows through the
cylinder and returns to the main process. When
retrieving a sample, the operator will close the
cylinder valves and turn the system to vent to
isolate the supply/return lines and allow the
fill lines to vent (1c). The operator will then
turn the system off before disconnecting the
cylinder. All images courtesy: Swagelok
PLANT ENGINEERING September 2020 • 41
SOLUTIONS
QUALITY ASSURANCE

Most systems are built with Operators can simply close the cylinder’s inlet and
316 stainless steel, but some outlet valves and turn the system to vent when the
system requirements may sample is ready for removal. Then, they can close the
call for higher-performing system’s inlet valve to stop the flow and remove the
alloys such as 400 and C-276 cylinder for transport to the lab. Inside the cylinder,
to ensure compatibility and the sample remains under the same process conditions,
eliminate corrosion issues. except for temperature, and as a result should be highly
• Purging Needs. Regular representative of the main process itself.
2a 2b system flushing helps Though cylinders can be used for gas or liquid
fight against contamina- samples, there are some critical distinctions for each.
Figure 2: tion and corrosion, so be sure to add a purge setup for Most importantly, flow paths should be different for
When using removing residual process fluids from grab sampling gases and liquids to enable the purging of any out-of-
cylinders, gas system lines. phase fluids from the cylinder, as follows:
samples (2a) System designers should be sure to think through • Gases should flow from the top of the cylinder
should flow each of these considerations when specifying a grab down (as shown in Figure 2a), pushing out any
from the top sampling system for their facilities. liquid or condensate from the sample cylinder as
down to push it fills. This ensures liquid will not collect in the
out any liquid Sampling with cylinders cylinder and interfere with analyzer readings.
or solid as Numerous options are available for gas or liquid sam- • Liquids should fill from the bottom up (shown
the cylinder pling with cylinders. One common, highly efficient in Figure 2b). This helps displace the vapor space
fills. Liquid design is a closed-loop system, which draws a sample and ensure the cylinder is full. An outage tube can
systems (2b) from a positive-pressure process and returns it to the be added to cylinders capturing liquid samples to
should be process at a lower-pressure location. This system uses maintain expansion space in the cylinder, as the
designed to differential pressure to drive the fluid through the trapped vapor may compress under pressure. (see
fill from the sample system. The sample continuously circulates the “Outage Tubes Explained” sidebar).
bottom up, through the cylinder while the operator takes a sample.
so the sample Closed-loop systems reduce the need for purging Of course, safety is important here, too. Ensure that
displaces the because the sampling system effectively becomes an any cylinders used for gas or liquid samples comply
vapor space. extension of the main process system. When the grab with all appropriate safety regulations.
sampling system inlet valve is opened, process fluid
flows through the system and the sample cylinder, Bottle sampling in liquid applications
then flows out to the outlet port (see Figure 1). Older Liquid-only grab sampling using bottles involves draw-
process fluid remaining in the short inlet line will be ing fluid directly from the process into non-pressurized
flushed through the closed-loop path, returning to the bottles. Bottle sampling can be a more economical
main process system as the cylinder fills. solution in suitable applications, and the clear glass
structures are good for immediate visual checks on
Figure 3: This bottled grab sampling system design (3a) is used quality.
when continuous flow is required from inlet to outlet. When Bottle sampling is a good choice for process fluids
the operator opens the spring‐loaded sampling valve (3b), that are not susceptible to fractionation or evaporation
process fluid flows into the bottle, while also continuing to flow when the sample is at atmospheric pressure. Note that
through the bypass. any increase in internal pressure may cause loss of
sample through the lid or septum cap seal — accord-
ingly, liquid bottle systems should be used with water
or other low-vapor-pressure liquids.
In suitable applications, first determine whether
continuous flow and purging are required. Continu-
ous flow comes in handy when the sample requires
constant motion, or when a long tubing run leads up
to the sample point. Under a continuous flow regi-
men, the sample flows through a bypass loop in the
grab sampling system and avoids sitting in tubes for
extended periods, ensuring the sampled fluid remains
representative. The sample bottle is then filled using a
3a: Front 3a: Back 3b spring-loaded sampling valve (shown in Figure 3). A

42 • September 2020 PLANT ENGINEERING www.plantengineering.com

 Outage Tubes Explained
Outage tubes (Figure 4) can be used as a safety mechanism in liquid cylinder sampling.
An outage tube enables a defined volume of vapor space to stay inside the cylinder while
capturing a sample, allowing the liquid to expand if temperature increases. Without enough
space, a small temperature increase can cause liquid expansion and dramatic pressure
increases, which can compromise operator safety.

The length of the outage tube determines the amount of vapor space, per the calculation %
Outage = (Vapor Space/Total Volume) x 100.

purge assembly should be used if the sampled fluid has
the potential to solidify, as it will help the dispensing
needle and internal tubing stay clean.
Fixed-volume systems are advantageous if the liq-
uid is highly pressurized or hazardous. This type
of system effectively isolates the user from process
pressure while limiting the fluid volume dispensed.
Here, the sample first fills a metal cylinder before
being gently pushed into a sampling bottle by a low-
pressure purge gas, helping to protect against inad-
vertent overfilling.
When it comes to safety, liquid samples may need to
cool before operators are able to safely fill and retrieve
a bottle without risking burns or injuries.
Ensuring success
Careful selection of container type and
proper configuration of other system
variables can help any industrial oper-
ator maintain sample integrity. The
key to accurate analysis is ensuring
the captured sample is representative
of process conditions when collected and analyzed. Figure 4:
By following the tips in this article, designers and Outage tubes
operators can achieve more efficient, accurate, and safe help to prevent
analyzer results from their grab sampling systems. PE cylinder
overfilling
Matt Dixon is senior principal design engineer for when capturing
Swagelok Company. liquid samples.

SOLUTIONS
DISTRIBUTION CENTER PRODUCTIVITY
By James Figy

PC control redefines intralogistics

distribution center efficiency
How to move 67,000 garment shuttles, boost efficiency and communicate
through EtherCAT

D
istribution centers need to make every cubic
foot count. Material handling equipment
needs to be cost-effective and use ware-
house space efficiently. Since most con-
veyors sit close to the ground, they take up significant
space. SDI launched the JOEY Pouch Sorter system to
raise unit sortation to the ceiling and promote efficient
product transport.
“The system relies on automatic switches and gravity
accumulation to move pouches or garment hangers
effectively,” says Jim Suggs, CTO at SDI. “The first
system we commissioned in 2016 used 5,000 pouches
to sort about 3,000 units per hour, which is relatively
small. The second system used 67,000 shuttles to buffer
and sort 7,000 units per hour.”
Founded in 1970, California-based SDI provides
turnkey material handling systems complete with con-
trols and software for fast-paced distribution centers.
Its technologies include distribution center manage-
ment solution (DCMS) software, tilt-tray, garment-on-
hanger, bomb-bay (or split tray) sortation equipment
and the pouch sorter.

www.plantengineering.com PLANT ENGINEERING September 2020 • 43

SOLUTIONS
DISTRIBUTION CENTER PRODUCTIVITY

SDI is expert advanced enough,” explains Mike McCanney, SDI con-

at t hird-p ar t y trols director. “These options were also significantly
conveyors, high- lacking in terms of both memory and storage. With any
speed merges application, we always deliver our entire DCMS controls
and other systems. solution, even if it’s not entirely used, to enable easier
“We i nte g r ate upgrades or customizations to meet client demands
numerous intra- in the future. Therefore, the controller needs enough
logistics solutions. memory capacity to store that sizable project.”
We pick the best The new controls platform needed to convert and
provider for the repurpose existing code from SDI’s broad portfolio
application and with ease and help improve the company’s build process
combine the best when commissioning machines.
technologies with “As we started converting code, traditional PLC
Figure 1: All our top-tier unit sortation equipment,” Suggs says. platforms don’t support some of our fairly simple pro-
SDI solutions, The pouch sorter offered the potential to reduce gramming constructs,” McCanney says. “We wanted to
from new equipment size and expense. However, coordinating preserve what we call ‘the build,’ which is our method
intralogistics thousands of pouches in a single system required a for automatically mapping I/O terminals and points.
innovations powerful, reliable control and networking platform, This software uses site-specific drawings and a library
to traditional explains Kyle Upwood, senior controls engineer. “The of preconfigured code for unit sorters, carton sorters,
conveying pouch sorter is demanding from a controls response regular conveyors and other technologies to write the
systems, now point of view.” complete code project within hours. The commission-
use EtherCAT SDI recognized the limitations of its legacy automa- ing engineer visits the site, loads the code and hits ‘go.’”
and PC-based tion platform used on its unit sorter and conveying
automation solutions. Technological capabilities
technology. “For our auto-induct onto the unit sorters, for exam- What got our attention was the real-time communica-
Photo ple, we do the motion control on the metering itself tion speed of EtherCAT, Suggs says. The EtherCAT
courtesy: and automatically induct the products onto tilt-tray industrial Ethernet system enables a range of topologies
Beckhoff sorters,” Suggs says. “We also use high-speed merges, — including line, tree and star — and can incorporate
which require high-speed motion control.” up to 65,535 nodes per network segment. That’s useful
Engineers at SDI’s Florida-based controls division in widely distributed material handling applications.
were challenged to find controllers and a fieldbus for EtherCAT benefits helped SDI solve performance
such rapid response times. At the time, their previ- issues with its legacy fieldbus to enhance sorting appli-
ous vendor’s control software could not run on an OS cations, says Mark Olton, area sales engineer, Beckhoff.
above Windows 7, soon to be obsolete, and the soft- “EtherCAT allowed SDI to incorporate third-party
ware required outdated flowchart-style devices and networks, such as EtherNet/IP, AS-Inter-
Figure 2: Automation programming. The machine controllers face and PROFIBUS. The system openness inherent
software allowed SDI to offered extremely limited memory and in EtherCAT proved helpful, especially since most
preserve existing code depended on OPC DA to communicate distribution center customers are unable to simply
and easily use modern with other devices, which was super- rip and replace their entire network infrastructure.”
programming standards. seded by OPC UA long ago. SDI engineers also explored PC control technology
Photo courtesy: Beckhoff Besides performance, SDI engi- from Beckhoff. After several successful in-house tests
neers focused on on SDI conveying systems, they specified the Beckhoff
flexibility, scal- C6920 control cabinet industrial PC (IPC) due to the
ability and cost. power required by large and complex architectures.
The team looked “The C6920 is a powerful PC, and it works well
at value at time in the pouch sorter because of the high-performance
of purchase and demands and large number of scanners,” Upwood says.
overall for the For less demanding conveying and sortation systems,
product lifecycle. SDI scaled down to the Beckhoff CX5130 embedded
“The technol- PC. “While the C6920 remains important in many
ogy most automa- situations, we standardized on the CX5130 as our main
tion and controls machine controller. It comfortably provides the nec-
vendors offered essary performance level for most applications and
was simply not offers an optimal price point for us,” Suggs explains.

44 • September 2020 PLANT ENGINEERING www.plantengineering.com

 The same code can run on either controller without
requiring changes beyond the runtime license.
Software possibilities
The universal engineering environment and runtime
software allowed SDI to increase its capabilities while
preserving existing code. Unlike the previous platform,
TwinCAT offers programming in all IEC 61131-3
languages with object-oriented extensions as well as
computer science languages through its integration
into Microsoft Visual Studio.
“Using more modern programming methods has
changed how we create code,” McCanney says. SDI
also improved on its build process using TwinCAT
Automation Interface, which enables the automatic
creation and manipulation of TwinCAT eXtended
automation engineering (XAE) configurations.
The Automation Interface functionality is possible
using all COM-capable and dynamic script program-
ming languages, such as .NET, Windows PowerShell
or IronPython. The TwinCAT Automation Device
Specification (ADS) interface offered additional
benefits for commissioning and communication in
distributed, multi-controller architectures.
“TwinCAT treats individual software modules,
such as the PLC, independently as a server or client,
and ADS exchanges messages between these objects
within the system and over the TCP/IP connections,”
Olton explains.
As a device- and fieldbus-independent interface,
ADS eliminated the requirement for outdated OPC
DA in all new SDI applications. “With EtherCAT and
ADS as a backbone for cross-controller communica-
tion, we can implement a more distributed controls
environment with smaller controllers spread across
fulfillment centers,” McCanney says.
Intralogistics improvements
The pouch sorter allows SDI to optimize the exist-
ing footprint in distribution centers while increasing
throughput considerably. By transitioning its controls
platform to Beckhoff, SDI sees performance gains in
all solutions.
For the pouch sorter this has enabled installation
of larger and more complex applications, according
to Suggs. “A recent application for a large clothing
manufacturer boasts 67,000 shuttles with numerous
switches and 70 scanners where the shuttle makes
logic decisions in real-time,” he says. “This system
uses garment hangers, rather than pouches, on the
67,000 shuttles. It tracks the items, typically suits,
through various buffers to a matrix sortation system.
This automatically produces the stack sequence — a
small, medium and large suit, in that exact order —
www.plantengineering.com
before delivering
it to the packing
station.”
The upgraded
controls platform
results include
increased mes-
saging to the
database, accord-
ing to Upwood.
“We increased
the single point
machine rate by 58% to now over 10,000 units per Figure 3: The
hour. This was achieved while also increasing the JOEY Pouch
barcode cameras that are required to run at this new Sorter from
max rate by 40%. I/O points increased by 51%, and SDI maximizes
high-speed track switching devices increased by footprint
182%,” he says. utilization in
Less than two years after choosing Beckhoff, SDI distribution
migrated nearly all existing code to the new platform centers by
and enhanced its design and build processes. “There transporting
was a lot of concern when we first began shifting con- product
trol platforms about how easy it would be to convert through
our libraries of code. Beckhoff made it much easier unused space
than we anticipated,” McCanney says. along the
Some SDI code is deprecated or for discontinued ceiling. Photo
equipment, but the progress the company has made courtesy: SDI
in programming is significant. “With the last major Systems, Inc.
pieces that we had to finish, including the high-speed
merge and the auto induct, we are likely 85% com-
plete as of today,” Suggs says. “In addition, TwinCAT
Automation Interface greatly improved our capabil-
ity to create software that adapts well on every new
application.”
By implementing Beckhoff IPCs, SDI exceeded its
memory and processing power requirements, but it
also reduced cost compared to comparable offerings
from other vendors. “To get that amount of memory
from one particular competitor would have cost
$20,000,” McCanney says. “With Beckhoff, it just
feels like we’ve roared into the 21st century. I didn’t
realize how much our previous controls platform
was holding us back. For a company of our size to
deliver large-scale automated systems to major retail-
ers and apparel manufacturers, we benefitted greatly
by implementing Beckhoff as our standard platform.”
With increased controller and networking capabilities,
SDI can continue designing and implementing more
innovative pouch sorters and other material handling
innovations to further optimize floor space usage in
today’s distribution centers. PE
James Figy is senior content specialist, Beckhoff
Automation LLC.
PLANT ENGINEERING September 2020 • 45
SOLUTIONS
INPUTS/OUTPUTS
By Josh Eastburn

Edge I/O brings more connectivity

to field devices and sensors
Latest remote I/O combines IIoT communication with even more processing power
than traditional intelligent I/O

W
hen intelligent input/output (I/O)
systems first appeared, they were an
alternative to the prevailing options
at the time, including 1) low-cost I/O
for discrete control applications, often used with
programmable logic controllers (PLCs), and 2) more
expensive analog I/O for continuous control, typi-
cally part of large-scale distributed control systems
(DCS).
These early I/O systems were limited to converting
raw electrical signals into digital values. The burden
of processing, filtering and shaping these signals
to create clean, usable data for process control and
visualization rested completely on the controller.
The “intelligent” moniker given to new I/O sys-
tems pertains to their embedded computing power.
Rather than rely on the controller, they can perform
operations for signal processing and PID control
internally. Computing power reduced use of cus-
tom programming to perform common tasks, like
latching, counting, and thermocouple lineariza-
tion, relieving the burden on the controller (and
programmer).
Figure 1: Edge
I/O connects
real-world
electrical
signals
directly to
information
systems and
applications
on-premises
or in the
cloud. All
figures
courtesy:
Opto 22
Intelligent I/O also paved the way for other control
options, like distributed control, as well as hybrid con-
trol systems that addressed the needs of both discrete
and continuous control functions for large-scale appli-
cations. Since then, I/O systems continued to evolve,
now with the motive of addressing Industry 4.0 needs.
Changing needs in the field
Early intelligent I/O systems provided key distin-
guishing benefits:
• With extra processing power in a modular for-
mat, it was easier to add advanced functionality
to small and low-cost control systems.
• By distributing processing and control through-
out the system, intelligent I/O created options
for redundancy and fault-tolerance.
• With I/O modules handling signal processing
and PID loops locally, logic scan times decreased,
making systems more responsive.
• In short, the focus of these I/O options was to
create affordable, resilient, and responsive auto-
mation systems.
However, the push towards a digital transformation
introduces goals that begin with reliable automation
as a given and reach beyond operations technology
(OT) to connect with the information technology
(IT) domain in meaningful ways.
These new goals include:
• The convergence of IT and OT systems, open-
ing data silos
• Ubiquitous connectivity and communication
between field devices and software
• Machine-to-machine communication for predic-
tive analysis and autonomous control and
• Other productivity stepping stones, like mobile
and augmented visualization.
So generally, beyond reliability, control systems
are being asked to deliver more data and more con-
nectivity. However, some obstacles lie in the way to
achieving these goals.

46 • September 2020 PLANT ENGINEERING www.plantengineering.com


With most industrial data still residing in uninte-
grated sensors and switches and a large installed base
of standalone machinery across many brownfield sites,
the industry has a long way to go to achieve ubiqui-
tous connectivity. To complicate things further, the
traditional options for integration are RTUs, PLCs,
OPC and SCADA servers. These simply don’t scale to
the level needed to integrate everything, lacking the
communication and security protocols needed to do
so safely and incurring additional costs per I/O point
with every level of middleware required.
I/O to the rescue
Next to field devices themselves, I/O systems are
the closest point to highly prized field data. They
are also a required integration point for hardwired
equipment and its untapped data. Intelligent I/O
systems are targeting features that allow engineers,
technicians, and developers to tackle data integra-
tion efficiently and securely.
These systems are appearing in the market under a
variety of names, sometimes simply as “smart remote
I/O,” but the term “edge I/O gateway” is also com-
mon and helps to distinguish the unique functional-
ity they offer compared to previous generations. The
term is derived from the concept of edge computing,
a distributed architecture that relies on lightweight
local computing resources working in partnership
with heavyweight cloud services or data centers to
improve data processing and local performance.
Edge computing is finding applicability within
industrial internet of things (IIoT) applications
because of the need to support higher volumes of
data for business intelligence and analytics systems.
Industrial edge I/O modules and systems provide
even more computing power than traditional intel-
ligent I/O and apply it to data processing and IT
connectivity, in addition to enhancing basic control
www.plantengineering.com
Figure 2: New
intelligent
remote I/O
(edge I/O)
systems are
compatible
with IT
networks,
so they can
bypass the
usual layers of
middleware
to move data
directly from
the field to the
cloud.
functions. Rather than dealing only with I/O signal
processing, these devices can become part of the net-
work infrastructure, connecting field devices directly
to maintenance systems or business applications using
native protocols for communication and security.
Defining industrial edge I/O
Naturally, systems from various vendors differ in
their specific form factors and I/O options, but they
share a common feature set that addresses the specific
goals and obstacles of connected control systems.
More processing power: Distributed computing
power is the defining attribute of intelligent I/O.
Edge I/O takes it to the next level with faster CPUs
and more RAM to support complex signal process-
ing and embedded applications. Some models run
their own real-time operating systems on chipsets
like those powering modern mobile devices.
More connectivity options: Edge I/O connects
the real world to the digital world with a selec-
tion of communication interfaces that bridge both
domains. Typically, these devices offer a mix of I/O
types, analog and discrete inputs and outputs as
well as serial options. Importantly, though, edge
I/O complements these with multiple options for
transmitting information to automation and busi-
ness networks: wired Ethernet, WiFi, or cellular.
Support for OT and IT protocols: As opposed to
previous I/O systems that focused only on automa-
tion connectivity, edge I/O provides for native com-
munication with IT systems, as well. It pairs options
such as Modbus/TCP, EtherNet/IP, PROFINET,
and OPC UA with REST, MQTT with Sparkplug
B, SNMP, VPN, and other protocols that support
a completely new communication architecture for
I/O. With the combination of appropriate media
and protocols, edge I/O devices can translate raw
I/O signals into both OT- and IT-compatible data.
PLANT ENGINEERING September 2020 • 47
SOLUTIONS
INPUTS/OUTPUTS
Embedded security: Critically, IT compatibility
introduces security options that have frequently
been lacking in automation hardware. Features like
user authentication, SSL/TLS data encryption, cer-
tificate management, and internal firewall configura-
tion enable secure data transmission directly from
the field or plant floor, even across public networks.
Embedded logic: Secure IT communication and
embedded computing power make it possible for
edge I/O systems to take on even more of the tasks
typically given to a controller. In addition to tradi-
tional signal processing features like scaling, ramp-
ing, totalization, and output pulsing, edge I/O adds
simple programming options such as Node-RED to
store and filter data, combine data from different
sources, and execute transactions with databases
and web services.
What’s possible now?
What do these new I/O options do to move the
industry closer to a digital transformation and how
do they help to overcome the obstacles that stand
in the way?
Meeting the bandwidth and computing demands
of Big Data as well as the local requirements of
embedded artificial intelligence and advanced visu-
Figure 3: Edge alization requires industrial automation specialists
I/O combines to consider a new, more scalable system architec-
intelligent I/O ture. Edge computing is already demonstrating its
processing and effectiveness in commercial applications, and it
IT connectivity holds potential for industrial applications as well.
to simplify IIoT Unfortunately, ripping out existing infrastructure
applications, is an expensive proposition. Automation engineers
like monitoring need options that can run in parallel with existing
operational systems to achieve the same outcome.
effectiveness Edge I/O enables additional computing and net-
of remote working to be added piecemeal, in place of or in
equipment. addition to, existing automation infrastructure,
48 • September 2020 PLANT ENGINEERING
providing multiple paths for engineers to architect
scalable communications. For example:
• Edge I/O can be used for lightweight integration
by connecting I/O signals to data networks in
parallel with legacy automation systems.
• Hardwired equipment can be retrofitted with
basic sensors and edge I/O as a controller-less
integration option that sends data directly to
supervisory systems.
• Existing middleware such as PLCs and Windows
PCs can be bypassed or removed by allowing
edge I/O to handle data acquisition, prepro-
cessing, and transport to higher-level systems.
• Since many edge I/O models are designed for
hazardous locations, edge I/O also provides a
more affordable path to remote condition moni-
toring of hard-to-reach equipment.
In combination with edge controllers, edge I/O
makes available more design possibilities, particu-
larly for integrating legacy automation devices. But
it’s the controller-less potential of industrial edge I/O
that allows for flexible deployment of intelligence and
connectivity into the process. That kind of scalability,
with security as a first principle, helps to make large-
scale machine-to-machine communication feasible.
Gist of it
I/O systems continue to evolve in response to the
changing needs of the automation industry. Edge
I/O combines distributed intelligent I/O process-
ing with IT-oriented communication, expanding
the options for creating ubiquitous connectivity
and overcoming obstacles to total integration. The
critical differentiator between these systems and
previous generations of intelligent I/O is their ability
to interface with IT systems and software natively,
allowing them to bypass traditional communication
middleware and send data
directly to its destination.
The same capability allows
these systems to share a
larger scope of responsi-
bility in automation tasks
and to act independently
of traditional automation
controllers such as PLCs,
PACs or IPCs. PE
Josh Eastburn is director of
technical marketing at Opto
22, Temecula, CA. He is a
contributing writer at blog.
opto22.com.
www.plantengineering.com
SOLUTIONS
DIGITAL TRANSFORMATION
COVID-19 accelerates digital
transformation
Rapid production changes, enterprise-wide connectivity and a shift to proof
of value for IIoT implementations.
H
ow is COVID-19 affecting digital trans-
formation? CFE Media had questions
for software connectivity company PTC
about how the COVID-19 pandemic
was changing digital transformation. Sean Callahan,
senior director, strategic marketing for Kepware, part
of PTC, provided answers about digital transforma-
tion value, enterprise-wide connectivity and Indus-
trial Internet of Things (IIoT) proof of value. PTC’s
solutions combine augmented reality, industrial IoT,
PLM, and CAD. Kepware has the connectivity and
IIoT part down cold.
Question: How has COVID-19
impacted marketplaces, industries,
and/or supply chains?
Callahan: COVID-19 has been a catalyst for compa-
nies accelerating their digital transformation journeys.
Industrial organizations have now seen firsthand the
value that digital transformation brings when dealing
with crisis situations, or when they need to rapidly make
shifts in production and are responding accordingly.
Many organizations that did not undertake major
digital transformation efforts ahead of the pan-
demic were more negatively impacted as a result.
We have found that they are now evaluating and
making plans to quickly implement transformative
technologies in the future such as the industrial IoT
and augmented reality (AR). Demand for these tech-
nologies, as well as critical foundational technolo-
gies like enterprise-wide connectivity, continues to
grow as organizations evaluate how they’ll position
themselves to thrive post-crisis.
Q: How will COVID-19 shape mar-
kets with technologies and systems;
people and training; and processes
and quality control?
Callahan: The most tangible example of COVID-
19 disrupting products, processes, and people is
with training and digital work instructions. Facing
www.plantengineering.com
rapid changes in demand, new social distancing
measures, and the rise of remote work, industrial
organizations needed new approaches to onboard-
ing, training, upskilling, and reskilling that worked
within the new normal they were facing. To main-
tain business continuity and help their employees
navigate these challenges, manufactures are now
leveraging AR to capture and transfer knowledge
– to employees, to customers, and even to other
manufacturers.
Q: With global economics, what
changes do you foresee in the upcom-
ing 1 to 3 years to recover from this
pandemic and better prepare for next
potential pandemic or crisis?
Callahan: As a direct result of the pandemic, we
are seeing companies create short-term and long-
term plans to help them weather the crisis and better
prepare for future uncertainty. These crisis response
plans prioritize employee safety while also focusing
on improving overall productivity, securing alternate
material supplies and alternative production options,
and embracing rapid retooling efforts that would
enable more flexibility to produce products not in
the company’s immediate supply chain.
To help industrial organizations navigate the crisis
short-term, PTC offered its remote assistance soft-
ware free of charge, enabling manufacturing and
service organizations to keep employees both con-
nected and safe during the pandemic. In the short-
term, programs like these helped companies maintain
business continuity while enabling them to free up
liquidity for other immediate needs.
From a more long-term perspective, we are find-
ing that conversations around overall efficiency and
cost saving measures are dominating the planning
landscape as companies look to ensure ongoing busi-
ness continuity. Carrying over from their short-term
plans focused on maintaining free cash flow, many
companies are scaling back on overhead to ensure
liquidity in the case of future crises.
PLANT ENGINEERING September 2020 • 49
SOLUTIONS
DIGITAL TRANSFORMATION
While reducing cost remains top-of-mind, many
organizations are investing heavily in a joint IoT and
AR strategy to drive digital transformation initiatives
and ensure that they will be properly suited to weather
a crisis should another one arise. For many industrial
organizations, their most important strategic moves are
focused on enabling remote work and remote service.
Organizations with complex machinery that
requires in-person maintenance anticipate that
similar facility shutdowns and border closures in the
future will impact their ability to service customers
– something that a major automation manufacturer
experienced in this pandemic. Leveraging software
tools the company enabled its internal expert to walk
service representatives in the field through complex
maintenance procedures, thereby ensuring the ability
to keep its service team members safe throughout a
pandemic in a manner that is easiest for the customer
without sacrificing product quality.
Q: Covering teamwork and collabo-
ration, how will engineering teams
evolve in the coming months, using
communications and productivity
tools to drive efficiencies?
Callahan: As organizations look to gain efficien-
cies, we are seeing teams from OT and IT [operational
technology and information technology groups] work
together more strategically, driving industrial IoT ini-
50 • September 2020 PLANT ENGINEERING
Figure 1: Industrial connectivity tools, such
as the ThingWorx Kepware Server, can
connect existing assets without replacing
machines, enabling industrial organizations
to demonstrate real proof of value without
disrupting production on the most critical lines.
Image courtesy: PTC
tiatives together to realize tangible business outcomes
for both groups. We are also seeing a shift from a focus
on “proof of concept” implementations to a focus on
“proof of value.” Proof of concept implementations
were typically deployed in an area of the shop floor
that was less risky to test new technology on – but the
problem was that with these low-risk, low-priority
pilots, companies could not see the value that would
be realized by scaling these to more impactful areas
of the business. By shifting to a proof of value imple-
mentation, they are targeting the areas of the business
where they can realize the largest impact and value.
To do this successfully, they are looking for solutions
they can get running quickly without disrupting the
manufacturing process in the critical areas targeted
for these high-value pilots. Industrial connectivity
tools provide the ability to connect existing assets
without replacing machines, enabling industrial orga-
nizations to demonstrate real proof of value without
disrupting production on their most critical lines.
Q: How will engineers in manufactur-
ing help economic growth return?
Callahan: We are seeing that manufacturing engi-
neers are using this time to research, design, imple-
ment, and empower digital transformation strategies
in their organizations. We are also seeing their organi-
zations, in turn, make commitments with global sys-
tems integrators and consultants to ensure they lock
up the best resources for enabling digital transforma-
tion as soon as the economy reopens. In supporting
the broader digital transformation economy, as well
as strengthening their own businesses, manufacturers
are leading the way to helping us return to a period
of economic growth.
As we learn to embrace the new normal, manufactur-
ers will be uniquely poised to educate other industries
about how to jump-start their own recovery efforts –
sparking broader discussions about employee safety,
workforce productivity, and overall efficiency gains
resulting from investment at this critical juncture. PE
Sean Callahan is senior director, strategic market-
ing for Kepware. Edited by Mark T. Hoske, content
manager, CFE Media, mhoske@cfemedia.com.
www.plantengineering.com
INNOVATIONS NEW PRODUCTS FOR ENGINEERS

Power monitoring software

EcoStruxure power monitoring expert from Schneider
Electric is a complete, interoperable and scalable purpose-
built software system dedicated to power management
that enables users to improve operational efficiency and
reduce energy-related costs, ensure electrical network
reliability and optimize equipment utilization and the cost
of operations.
Schneider Electric
www.se.com
Input #200 at www.plantengineering.com/information

EJ-series plug-in modules

EJ-series plug-in modules from Beckhoff Automation make it easy
to implement a platform concept for large-volume production
runs without sacrificing customization capabilities. The modules,
with electronics based on the popular EtherCAT input/output
(I/O) system, are directly inserted into an application-specific
signal distribution board that transmits signals and power to
the individual connectors. Connections via preconfigured cable
harnesses replace the expensive installation of individual wires,
reducing per-unit costs and minimizing the risk of faulty wiring
because the EJ components are clearly coded.
Beckhoff Automation
www.beckhoff.com
Input #201 at www.plantengineering.com/information

Capacitive discharge power supplies

The CD-A series capacitive discharge power supplies from Amada Weld Tech
features dual pulse output control, internal pulse monitoring, optional polarity
switching and is automation capable. They are ideal for battery tab welding,
interconnects, honeycomb tacking and fine wire to pad applications. The
units offer consistent welding output for repeatable process results with fast
rise time for conductive material welding. The CD-A series provides pulse
shaping with four discrete pulse lengths, programmable squeeze and hold
times and adjustable pulse separation for process optimization.
Amada Weld Tech
https://amadaweldtech.com
Input #202 at www.plantengineering.com/information

www.plantengineering.com PLANT ENGINEERING September 2020 • 51

INNOVATIONS
High flexing control cable
High flexing control cable organizes control signal wiring
in constantly moving applications such as robotics or high
mechanical loads. With no special tools, the cable’s jacket
can be opened like a zipper to a desired length, saving
time for assemblers and electricians. Order cable cut to
your specified lengths, or in any bulk length. Features
include unshielded and shielded constructions, individual
conductors with black TPE insulation marked with white
identification numbers and sunlight/oil resistant/flame
retardant/low adhesion pressure extruded TPE mixture
outer jacket.
AutomationDirect
www.automationdirect.com
Input #203 at www.plantengineering.com/information
Control IPC with slice
I/O expansion
The AMAX-5000 series EtherCAT Slice
I/O and controller from Advantech
designed with the smallest programmable
automation controller (PAC) in the Core
i class, modular input/output (I/O) and
PCIe communication interface. This latest
addition to the AMAX series provides
users with an easy to integrate and
arbitrarily scalable solution. The AMAX-
5000 features compact size, high-speed
processing, flexible expansion and a
high degree of integration. This series
also offers an AMAX-5580 embedded
controller, the EtherCAT I/O module
AMAX-50xx series and PCIe module
AMAX-54xx series.
Advantech
www.advantech.com
Input #204 at www.plantengineering.com/information

Brass Spur Gears

Brass spur gears from Custom Machine and Tool Co. Inc. are bored to accept the patented Concentric
Maxi Torque, a keyless connection bushing system. Spur gears are common gears that transmit motion
between two parallel shafts. The gears are used in applications that require
speed reduction and torque multiplication such as size reduction equipment,
consumer appliances, trains and bicycles. Flexible positioning enables users to
easily phase, install, adjust and remove drive components while offering precise
component positioning. The Concentric Maxi Torque bushing system provides
uniform surface contact and a compact design.
Custom Machine and Tool Co. Inc.
www.cmtco.com
Input #205 at www.plantengineering.com/information

52 • September 2020 PLANT ENGINEERING www.plantengineering.com

 NEW PRODUCTS FOR ENGINEERS

Predictive analytics software

for the auto industry
The Intelligent Pneumatic Runtime Monitoring
software from Festo with artificial intelligence (AI) from
Resolto, a member of the Festo Group that specializes
in AI development, alerts the auto manufacturer to
replace clamps during routine maintenance periods to
avoid costly unplanned shutdowns due to unforeseen
failures. This AI-based algorithm relies on signals from
the valves and the end positions of the actuators for its
diagnostics – information that is readily available.
Festo
www.resolto.com
Input #206 at www.plantengineering.com/information

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www.plantengineering.com PLANT ENGINEERING September 2020 • 53

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Input #103 at plantengineering.hotims.com Input #104 at plantengineering.hotims.com Input #105 at plantengineering.hotims.com

54
54 September
•• Month 2014
2017_PLE_eNews_SixthPage.indd 1 2020
PLANT ENGINEERING
PLANT ENGINEERING
2/13/2017 11:17:31 AM www.plantengineering.com
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www.plantengineering.com PLANT ENGINEERING September 2020 • 55

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56 • September 2020
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PLANT ENGINEERING www.plantengineering.com and
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input #13 at www.plantengineering.com/information

—
Safer food
Comes from safer designs

To ensure uptime and safe food production, don’t let bearings be the weak link
in your process. Dodge® Food Safe bearings are the first to achieve IP69 for
water protection rating without the use of an end cover and be warranted
against failure due to water ingress; making them ideal in environments where
equipment must be aggressively cleaned. Dodge Food Safe bearings improve
reliability of clean-in-place procedures and provide you, and your customers,
with the safe production you expect.

Improved cleanability. Extended life. Reduced maintenance.

Dodge Food Safe bearings

new.abb.com/mechanical-power-transmission
input #14 at www.plantengineering.com/information