control engineering_

r[n] + e[n] Controller u[n] u[t] Controlled y[t] CPU/DSP D/A system Set point (reference input) - y[n] A/D CONTROLENG.COM Oil & Gas Engineering | 37 Enhanced control with IIoT? | 44-51 Seeing better machine vision | 55 Automation education | 27, 57 Inside Machines after | 58

Motion in sync is easier than you think with motion controllers from AutomationDirect PS-AMC Motion Controllers starting at: $284.00 (PS-AMC1) 4 The PS-AMC motion controllers are designed to 2 1 work seamlessly with select Productivity PLCs 3 and provide accurate, coordinated, plug-and-play Flying cut-off motion control. Up to 16 independent axes of motion control, or up to four groups of The primary function of a flying cut-off system coordinated motion with four axes each, is is to synchronize the speed of a servo-driven possible with these new controllers. carriage, on which a cutting mechanism is mounted, with the speed of a continuously fed material to • Available in 1, 2, 3, or 4 axes models make a perpendicular cut without stopping the feed. The flying cut-off shown above employs four • Maximum switching frequency of 1MHz axes of motion, a rotating pipe cutter1, a continuous pipe infeed system2, carriage positioning drive3, and • Up to 24 general-purpose high-speed inputs outbound conveyor4. With the PS-AMC4, all four of these axes can be easily controlled and synchronized within • Up to 12 general-purpose high-speed outputs the same controller, and it's only $465.00! • Easy configuration of standard motion PS-AMC compatible profiles (flying cut-off, rotary table, etc.) Productivity PLCs with the FREE Productivity Suite software and built-in motion instructions starting at: ProductivitySeries $221.00 (P1-550) Research, price, buy at: www.automationdirect.com/motion-controller-productivity Order Today, Ships Fast! * See our Web site for details and restrictions. © Copyright 2022 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation input #1 at www.controleng.com/information

Slotted Aluminum Rails Cut how you need it and shipped fast TM NO CUT FEES, EVER! CUT TO YOUR SPECIFICATION AND DELIVERED TO YOU IN 2 DAYS! SureFrame T-Slotted Aluminum Rails Features • You specify length and cut angles for each piece SureFrame T-slotted aluminum rails are available • No cut fees in the most popular profiles and dimensions. • Free 2-day delivery on all orders over $49* T-slotted rails are ordered in your custom • Available in 1 inch, 1.5 inch, 30mm, 40mm and 45mm profiles cut-to-length sections for maximum flexibility • Complete selection of Fath installation hardware available and minimum waste. Research, price, buy at: We also offer a full selection of assembly hardware for T-slotted rail systems, which includes T-nuts, www.automationdirect.com/t-slotted-rails fasteners, connecting components, joining plates and brackets, as well as floor, door and panel elements. SureFrame T-slotted rails, along with the assembly hardware components offered, are compatible with many other brands. Also Available • AC variable frequency drives (VFDs) • Motors • Wiring and electrical connection solutions • Just about everything you need to complete your automation projects! Order Today, Ships Fast! 1-800-633-0405 the #1 value in automation * See our Web site for details and restrictions. © Copyright 2022 AutomationDirect, Cumming, GA USA. All rights reserved. input #2 at www.controleng.com/information

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Vol. 69 • No 3 APRIL 2022 r[n] + e[n] Controller u[n] u[t] Controlled y[t] 30 CPU/DSP D/A system Set point COVER: A large polymer (reference input) - plant used the loop tuning y[n] toolkit embedded in its A/D Emerson DeltaV distributed control system to reduce startup time and increase production rates. Courtesy: Emerson INSET: Block diagram shows a digital closed-loop control system. Courtesy: Peter Galan, retired control software engineer INSIGHTS ANSWERS 11 | International: Digital field instruments 30 | The control system is key to optimal p.19 accelerate petrochemical, process loop tuning Links p.44 industries 33 | PID-correction-based control system ONLINE 15 | Market Update: Semiconductor implementation Online highlights: pages fab spending projected to exceed 5, 7, 8 and throughout this $100 billion in 2022; Manufacturing 37 | Oil & Gas Engineering issue. output strong in 2021; Manufacturing technology orders rose in 2021 44 | Industrial IoT made fast and easy and TechnologyTM 16 | Technology Update: Water energy 48 | Six ways IIoT expands manufacturing reclamation for process facilities system capabilities 19 | Technology Update: Advancing flue-gas 51 | Industrial networking enables flow monitoring techniques IT, OT integration, benefits NEWS 55 | Machine vision, machine p.51 24 | Three robotic automation trends in 2022, control convergence with PC-based automation Quantum computing project launched in Germany, Online Headlines 57 | Educational opportunities and 27 | Think Again: Automation, robotics, developments for engineers AI, ransomware INSIDE MACHINES M1 | Understanding the key components of a labeler machine CONTROL ENGINEERING (ISSN 0010-8049, Vol. 69, No. 3, GST #123397457) is published Monthly, except in January and November by CFE Media, LLC, 3010 Highland Parkway, Suite #310 Downers Grove, IL 60515. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. POSTMASTER: Send address changes to CONTROL ENGINEERING, PO Box 348, Lincolnshire, IL 60069. Jim Langhenry, Group Publisher/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2022 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Circulation records are maintained at 3010 Highland Parkway, Suite #310 Downers Grove, IL 60515. Telephone: 630/571-4070. E-mail: [email protected]. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: PO Box 348, Lincolnshire, IL 60069. Email: [email protected]. Rates for nonqualified subscriptions, including all issues: USA, $165/yr; Canada/ Mexico, $200/yr (includes 7% GST, GST#123397457); International air delivery $350/yr. Except for special issues where price changes are indicated, single copies are available for $30 US and $35 foreign. Please address all subscription mail to CONTROL ENGI- NEERING, PO Box 348, Lincolnshire, IL 60069. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever. control engineering — www.controleng.com |April 2022 3

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Vol. 69 • No 3 Contents APRIL 2022 INNOVATIONS uThe Book on Marketing to Engineers People often seek New Products for Engineers help to market to engineers. “The 62 | Differential measurement system; Cable and network tester; Book on Market- ing to Engineers®” Industrial DIN-rail switches; Profinet-enabled peristaltic pumps; Cloud- by CFE Media and based monitoring solution for water networks; Energy monitoring unit; Technology cov- Hazardous location connectors. ers content mar- See more New Products for Engineers at keting, marketing www.controleng.com/NPE. tactics, branding and advertising, the buyer’s journey and other topics. More than 100 pages Back to Basics contain research analysis, video presentations and expert interviews to help. 64 | Industrial communication moving networks to the edge Learn more at https://pages.services/go.cfeme- dia.com/the-book-on-marketing-to-engineers/ Edge computing can help determine the status of device, machine, line, and plant health, which can be used to identify optimization opportunities. uGlobal System Integrator Report Supplement to December NEWSLETTER: Information Control Control Engineering and Plant Engineering. Advice from • Five improvements made by incorporating automation and control sys- situational awareness in an HMI tem integrators with System Integrator of the Year for 2022, • How automation can bolster information System Integrator Giants control in a factory and more. www.controleng.com/GSIR • Quantum computing project launched in Germany uControl Engineering digital edition The tablet and digital • How to select the right free-standing editions provide links to industrial enclosure additional article images and text online and links • Industrial servers: Easy to deploy, manage, to other related, useful support with hot-swapping components resources. Keep up with emerging trends: subscribe. www.controleng.com/ www.controleng.com/newsletters. magazine CFE Edu: Virtual Training Week On-Demand |April 2022 5 Did you miss the live event? You can still attend CFE Media and Technology’s Virtual Training Week on-de- mand to receive training on a variety of the latest industry trends. Register and receive full access to exclusive content offered by industry experts with live Q&A sessions! Virtual Training Week topics, courses, instructors: https://cfeedu.cfemedia.com/learning-paths/ cfe-media-technology-virtual-training-week control engineering — www.controleng.com

ur ast. Data security has never been more critical Skkynet’s unique DataHub technology is redefining industrial IoT. DataHub New security enhancements, unmatched tunneller capabilities to bridge on-premise and cloud, unparalleled flexibility with MQTT enhancements, and connection to historians now available in DataHub10. And, you can future proof your system with alarms and event notifications. One solution that does it all. Secure, fast, easy. SECURE INDUSTRIAL IoT REDEFINED Learn more at: Skkynet.com DataHub® is a registered trademark of Real Innovations International LLC, used under license input #5 at www.controleng.com/information

controleng.com Online Highlights Making a “computer” out of liquid crystals —Louise Lerner, University of Chicago uRESEARCHERS with the University of Chicago Pritzker School of Molecular Engineering have shown for the first time how to design the basic elements needed for logic operations using a kind of material called a liquid crystal—paving the way for a completely novel way of performing computations. The results are not likely to become transistors or computers right away, but the technique could point the way towards devices with new functions in sensing, computing and robotics. SIMULATION IMAGE showing self-assembly of two MNPs under a magnetic field. Courtesy: Yaroslava “We showed you can create the elementary building blocks of a cir- Yingling and Akhlak Ul-Mahmood, North Carolina State University cuit, gates, amplifiers, and conductors, which means you should be able to Multi-functional magnetic assemble them into arrangements capable of performing more complex nanoparticles simulations help sensor technology operations,” said Juan de Pablo, the Liew Fami- —Matt Shipman, North Carolina State University ly Professor in Molecular Engineering and senior uRESEARCHERS at North Carolina State Uni- scientist at Argonne National Laboratory, and the versity have developed a computational tool that allows users to conduct simulations of senior corresponding author on the paper. “It’s a multi-functional magnetic nanoparticles in unprecedented detail. The advance paves the really exciting step for the field of active materials.” way for new work aimed at developing mag- netic nanoparticles for use in applications The research aimed to take a closer look at a from drug delivery to sensor technologies. type of material called a liquid crystal. The mole- “Self-assembling magnetic nanoparticles, or MNPs, have a lot of desirable properties,” RESEARCHERS with the Uni- cules in a liquid crystal tend to be elongated, and said Yaroslava Yingling, corresponding author versity of Chicago Pritzker when packed together they adopt a structure that of a paper on the work and a Distinguished School of Molecular Engi- has some order, like the straight rows of atoms in a Professor of Materials Science and Engineer- neering laid out how liquid diamond crystal, but instead of being stuck in place ing at NC State. “But it has been challenging to crystals could be used to as in a solid, this structure can also shift around study them, because computational models perform computations using as a liquid does. Scientists are always looking for have struggled to account for all of the forc- techniques such as the one these kinds of oddities because they can use these es that can influence these materials. MNPs illustrated above, where the unusual properties as the basis of new technolo- are subject to a complicated interplay between redder region is activated by gies, such as liquid crystals in flat display screens. external magnetic fields and van der Waals, light. Courtesy: Rui Zhang, electrostatic, dipolar, steric, and hydrodynamic University of Chicago interactions.” Mobile robot use on the rise in manufacturing Many applications of MNPs require an understanding of how the nanoparticles will —Jordi Artigas, ABB Robotics behave in complex environments, such as using MNPs to deliver a specific protein or uTHE NEED FOR manufacturing and logistics companies to meet con- drug molecule to a targeted cancer affected sumer demands for greater choice and faster delivery, against a back- cell using external magnetic fields. drop of a shrinking labor pool, is leading new ways of automating. Mobile manipulators that combine autonomous mobile robots (AMRs) and robot |April 2022 7 arms represent the next quantum revolution in mobility and have already begun to be deployed in a growing range of applications. Adding manip- ulator arms on the AMR allows automation to be taken where needed. Recent developments in vision, navigation and artificial intelligence (AI), coupled with significant reductions in cost, allow AMRs to react in real time to operating environments, avoid obstacles and optimize routes. control engineering — www.controleng.com

controleng.com Online Highlights Logistics 4.0 and the mobile industrial robot —Brendon Turner, FlexQube uAT THE HEIGHT of the COVID-19 pandemic, supply chains and internal logistics processes across the globe witnessed their fair share of disruption. The need to secure supplies closer to home and implement social distancing within industrial facilities meant the industrial sector had to get innovative quickly. To ensure operator and material safety in a pandemic world, industri- A THEORY by Rice researchers suggests growing graphene on a surface that undulates like an egg crate al facilities accelerated their adoption of digital transformation solutions and would stress it enough to create a minute electromag- netic field, which could be useful for creating 2D elec- automation technology. Thus, a pandemic inadvertently increased the imple- tron optics or valleytronics devices. Courtesy: Henry Yu, Rice University ‘Logistics 4.0 refers to the mentation of Logistics 4.0 concepts application of digitalization across the globe. Graphene on textured surface allows for 2D electron optics What is Logistics 4.0? —Mike Williams, Rice University to create cyber-physical Logistics 4.0 refers to the appli- uRICE UNIVERSITY SCIENTISTS put forth solutions with the capacity cation of digitalization to create the idea that growing atom-thick graphene on cyber-physical solutions with the a gently textured surface creates peaks and valleys in the sheets that turn them into “pseu- to automate and gain capacity to automate and gain real- do-electromagnetic” devices. real-time control of logistics time control of logistics networks. The channels create their own minute but The digitalization and automated detectable magnetic fields. According to a study by materials theorist Boris Yakobson, ’networks. solutions that can be applied include alumnus Henry Yu and research scientist Alex Kutana at Rice’s George R. Brown School of the use of simulation modeling, Engineering, these could facilitate nanoscale optical devices like converging lenses. They digital twin, edge hardware, and mobile industrial robots to automate logis- also promise a way to achieve a Hall effect — a voltage difference across the strongly con- tics management. ducting graphene — that could facilitate val- leytronics applications that manipulate how The goals of Logistics 4.0 are similar to Industry 4.0 and they include the electrons are trapped in “valleys” in an elec- tronic band structure. ability to gain insight from captured logistics data to automate logistics pro- Valleytronics are related to spintronics in cesses and optimize material or supply flow. Logistics 4.0 is also expected to which a device’s memory bits are defined by an electron’s quantum spin state. In valleytron- be agile and support flexible industrial processes to maximize productivity. ics, electrons have degrees of freedom in the multiple momentum states (or valleys) they This means achieving Logistics 4.0 is integral to achieving Industry 4.0 goals. occupy. These can also be read as bits. How Logistics 4.0 works This is all possible because graphene, while Logistics 4.0 attempts to apply data analysis, automation, and digital it may be one of the strongest known struc- tures, is pliable enough as it adheres to a sur- transformation technologies to optimize both internal and external logistics face during chemical vapor deposition. operations. Here, internal logistics operations refer to the material handling system within a manufacturing or warehousing facility. Logistics 4.0 also control engineering — www.controleng.com focuses on creating an in terconnected system where the interexchange of data drives the system. The interconnected system usually consists of automated industrial robots tasked with the physical material handling process, IoT devices to monitor the system, the industrial cloud to centralize data aggregation, and edge devices to decentralize data analytics. This cyber-physical intercon- nected system also integrates the application of machine learning and AI to deliver diverse levels of autonomy to the material handling process. |8 April 2022

I2NK2E1LESPIIENNRGIEOEUSR 221 SERIES LEVER-NUTS® INLINE SPLICING CONNECTOR • Combines all the familiar advantages of 221 series Splicing Connectors into a slim design • Intuitive orange levers for a tool-free wiring experience for solid, stranded and fine stranded conductors from 12-20 AWG • Freedom of a highly modular & flexible connection with or without strain relief • Both fixed-position & multi-pole installations are possible with an adapter • Mounting carriers combine up to five connectors for multiple pole applications • Carriers may be placed on mini or standard DIN Rail or can be used for adhesive, tie-on or suspended mounting input #6 at www.controleng.com/information www.wago.us/ discover-wire-and-splicing-connectors/221

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INSIGHTS INTERNATIONAL Digital field instruments accelerate petrochemical, process industries Digital innovation of field instruments opens a new chapter of digitalization —Stone Shi, in the petrochemical and other process manufacturing industries. Control Engineering China Adigital factory cannot do without many this information, petrochemical and other pro- sensors to collect data. For petrochemical and other process manufacturing indus- cess industry customers can remotely monitor tries, field instruments are sensors. They are eyes and ears of an intelligent factories to collect instrumentation operational status and health, information in the production process and provide data support for production control, management and also can remotely manage instrument infor- and decision-making. mation. With instruments’ digital twins, all docu- With the continuous promotion of digital intel- ligence, what challenges does the petrochemi- ments and firmware will be automatically updated cal industry pose to field instruments? How can field instruments meet the digital transforma- and uploaded. Customers no longer need compli- tion needs of the petrochemical industry? During the 2021 China Smart Petrochemical Forum, an cated document collection, search and manage- interview with Zhang Yuncai, General Manager of Endress+Hauser (China) Automation Co., Ltd., a ment. Everything can be completed online, which well-known field instrument manufacturer, covered these topics. improves workflow efficiencies. Digitalization accelerates field At the same time, with the help of cloud technol- instrument product innovation ogy, Endress+Hauser is active in the construction For users in the petrochemical industry, data gathering is the first step toward digitization. To of digital supply chain to provide more efficient uOnline obtain more valuable data quickly and accurately, and creative changes for the operation and mainte- controleng.com higher requirements are asked of traditional instru- nance of modern chemical plants. At present, 90% ments, which requires digital product innovation. of Endress+Hauser's field equipment has been dig- KEYWORDS: itized. Each field instrument has a unique digital Instrumentation, process Yuncai said the digital transformation has lead identification and an IP address, giving full play to sensors, petrochemical Endress+Hauser to increase digital product offer- industry ings. In addition to the original five on-site mea- suring instruments (flow, material level, pressure, the potential of digital factory to enable additional LEARNING OBJECTIVES temperature and viscosity), additions include ana- field and remote capabilities. Learn how digitalization lytical instruments for water quality and gas, which accelerates field instrument are necessary for process industry digitization and “Not only that, digital products also give users a product innovation. data collection. good digital experience and make the transaction Examine how instrument Most Endress+Hauser instruments have dig- easier,” Yuncai said. heartbeats, cloud platform ital twins. All information such as production open a new chapter of information, status information and documents Endress+Hauser China has e-commerce plat- digitization. of instruments can be collected and used. With forms at different levels. The website helps compare product prices, place orders and track order status. See how cloud platforms For large customers, Endress+Hauser has B2B trad- enable instrumentation ing platforms through third parties, and its enter- applications and prise resource planning (ERP) system is connected cybersecurity. to the customer’s ERP system, which improves the digital trading experience for users and helps CONSIDER THIS make trading more efficient, simpler and more Are you serving your transparent. process instrumentation or is your process Instrument heartbeats, cloud platform instrumentation serving open a new chapter of digitization you? Machines, pumps, electrical appliances and ONLINE instruments are very important for the operation https://www.controleng. com/process- manufacturing/ sensors-actuators/ www.controleng.com/ international control engineering — www.controleng.com |April 2022 11

INSIGHTS INTERNATIONAL of the factory. The problem of any small equip- data and process data provided, allowing users to ment may affect the smooth operation of the whole target process optimization analysis. production line and the delivery quality of final products. Field instruments are the eye of building Yuncai said the heartbeat technology has been intelligent factory in petrochemical industry. Only applied to all Endress+Hauser products. Users have by ensuring the stability and reliability of instru- shown how heartbeat technology improves device ments can an intelligent factory become possible. stability and reduces the cost of use. Endress+Hauser launches its IIoT solution platform, Netilion, an ecosystem Netilion IoT cloud platform is based on asset combining digital services and system components to improve the lifecycle and management and use data from Endress+Hauser. asset management, maintenance, and support of instruments and analyzers. Field instruments can upload their information and Netilion enables users to keep track of their installed base, documentation and measurement data to Netilion anytime, anywhere, data management, and instruments’ performance and health status. Courtesy: and then use the tools and models on the cloud to Endress+Hauser, New Products for Engineers from CFE Media perform in-depth analysis of the data for preven- tive maintenance, advance prediction of production Digital technology can help ensure the sta- failures, and optimization of production processes. bility and reliability of field instruments. Endress+Hauser has launched a creative plat- Cloud platforms enable instrumentation form technology-heartbeat technology, and Netil- applications, cybersecurity ion, a cloud-based industrial Industrial Internet of Things platform, to improve the maintenance effi- “Based on the Netilion cloud platform, we ciency of field instruments and enable users gain have developed many applications that allow digitization value. users to view data from field instruments con- nected to the cloud platform via cell phone app Heartbeat technology refers to the technol- or computer browser anytime, anywhere, not ogy that enables instruments to be permanently only limited to Endress+Hauser instruments, but self-diagnostic, self-calibrating and self-monitor- also supporting instruments from other manu- ing without interrupting the process. Standardized facturers,” Yuncai said. diagnostic information provides clear operating instructions for efficient status-based maintenance. At present, Endress+Hauser already has IoT- Automatically generated calibration reports also enabled flow meters and level meters that can be can be used as audit documentation for regulations, connected to Netilion, while other meters also can laws and standards. Pre-maintenance trend identi- be connected to Netilion through a gateway. fication is achieved based on the instrumentation Of course, users don't have to worry about the safety of uploading data to Netilion, as Endress+Hauser has secured the Netilion ecosys- tem and connected meters in three ways: informa- tion security, cloud security and product security. The system has been certified by several third-par- ty international security certification bodies. “The combination of heartbeat technology and Netilion will produce greater value. The operations and maintenance (O&M) model of field instrumen- tation will be completely changed, and the previous passive, after-the-fact, manual experience-based maintenance model will become active, predictive maintenance that relies on data analysis, opening a new chapter in the digital factory of the petrochem- ical industry,” Yuncai said. ce Stone Shi is executive editor-in-chief, Control Engi- neering China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, [email protected]. |12 April 2022 control engineering — www.controleng.com

How to know when precision motion control is the right choice Patrick Wheeler | Product Manager – Controls @ Aerotech For many engineers working in the automation space, programmable logic controllers, industrial ethernet communication networks and sensors are common tools of the trade. Those tools are used in motor control applications such as controlling fans, pumps and blowers using AC motors; controlling process lines via torque and velocity control with high-powered brushed DC motors; microstepping control for precise applications using stepper motors; and controlling position, velocity and/or torque with servo motors. Each technology has its own benefits, and for the most part the world’s largest automation suppliers have an adequate solution no matter what technology is required. However, there is also a set of solutions aimed at a completely different level of motor control: precision motion control. Precision motion control solutions supply an even higher level of motor control, often synchronized over several axes of motion or motors. A common representation of precision motion control is the control of a CNC milling machine, which requires multiple axes of motion to move in complete synchro- nization in order to machine parts out of raw materials. However, precision motion control has a much broader appeal than this and can be advanta- geous in a variety of applications. This whitepaper will highlight some of the key differences between general automation and precision motion control. In addition, you will learn some indicators and signs that your process or application may require a precision motion control platform. Finally, considerations for selecting a motion control platform and supplier are reviewed. Read the entire white paper at: aerotech.com/CE032022-whitepaper aerotech.com input #8 at www.controleng.com/information

Leveraging a Standardized IIoT Ecosystem to Empower Innovative Business Models Challenge: Digital transformation brings challenges to automation development, including real-time data access, end-to-end security and multi-vendor integration/ interoperability. End users want to mobilize real-time remote operations and expand secure access to device/network data to increase productivity. Solution: The FDT (3.0) Unified Environment (UE) is focused on the Fourth Industrial Revolution, enabling a standardized IIoT ecosystem that empowers innovative business models, including customizable Server, Desktop and device DTM solutions, while supporting a data-centric, cross-platform IIoT platform. Result: Automation manufacturers and end users benefit from service-oriented business models supported by a completely open, interoperable and standardized IIoT platform. Recognized as an essential technology for the new era of automation—providing built-in mobility, native OPC UA integration, robust security, and platform independence—the FDT 3.0 UE ecosystem empowers IIoT and Industry 4.0 solutions for both Greenfield and Brownfield applications. The FDT UE ecosystem development environment Figure 1: FDT (3.0) simplifies the journey to innovative solutions that support Unified Environment standardized sensor-to-cloud data integration. With this approach, system and device suppliers can take a well-established standard and create customizable, data-centric, cross-platform FDT Server and device DTM solutions. The scalability, secure remote access and data-rich environment FDT 3.0 provides drives the realization of next generation automation solutions. At the core of FDT UE’s digital transformation pathway is the new FDT Server, which natively integrates an OPC UA Server for enterprise-wide IT/OT data access and a web server mobilizing remote operations. This innovative solution transforms asset management practices and business system integration for both automation suppliers and end users in the process, hybrid and discrete manufacturing markets. The enhanced developer toolkits available with FDT 3.0 reduce the burden of R&D work and save time and money when migrating existing FDT solutions or bringing new products to market. The toolkits are essential to improving quality and interoperability for the industrial installed base. Automation suppliers can obtain these tools directly from FDT Group and access the necessary licenses and standards for development initiatives. Download the full white paper on empowering innovative business models with FDT 3.0 at www.fdtgroup.org/innovation. input #9 at www.controleng.com/information

INSIGHTS MARKET UPDATE Manufacturing output strong in 2021 Semiconductor fab spending projected uInteract Analysis research shows the machinery growth. The USA performed to exceed $100 billion in 2022 pandemic has had marked effects on the better due to a lack of federal lockdowns and GLOBAL FAB EQUIPMENT spending manufacturing industry. While many a large stimulus. In 2022, the Americas (of for front-end facilities is expected to jump 18% year-over-year (YOY) to an all- machinery sectors are enjoying double- which the US is 72% of manufacturing out- time high of $107 billion in 2022, mark- ing a third consecutive year of growth digit growth, other areas continue to suf- put) will see 4.6% manufacturing growth. following a 42% surge in 2021, SEMI announced in its quarterly World Fab fer due to supply chain issues and chip Asia, excluding India, has handled the Forecast report. shortages. Output growth of 8.3% in 2021 pandemic best from a manufacturing per- “Global fab equipment spending is forecast to have another healthy year in has been recorded as manufacturing spective. In 2022, manufacturing growth of 2023 and is expected to remain above the $100 billion mark,” said Sanjay Mal- recovers from the 7% and machin- hotra, vice president of corporate mar- keting and the market intelligence team pandemic. After ‘8.3% output growth in 2021 ery growth of 6.5% at SEMI in a press release. “We expect the 2009 finan- growth are project- global semiconductor capacity to main- cial crash, manu- has been recorded as manufactur- ed. These numbers tain steady growth this year and in facturing output are understated 2023.” growth in 2010 ’ing recovers from the pandemic. because China con- Fab equipment was 16%.) The tributes to 69% of spending by region last crash saw production in the Taiwan is expected to lead fab manufacturing shrink by 8.3% in 2009; region and did not shrink in 2020. Without equipment spending in 2022, increas- ing investments 56% YoY to $35 billion, 2021 declined only 3.2%. China, growth for the region would be 9.6% followed by Korea at US$26 billion, a 9% rise, and China at $17.5 billion, a 30% The machinery sector is more volatile and 11.5% in manufacturing and machin- drop from its peak last year. Europe/ Mideast is forecast to log record high because the machinery market is 1/20th the ery, respectively. Supply chain disruption spending of $9.6 billion this year, and while comparatively smaller, it still rep- size of the overall manufacturing market; and the shipping crisis has caused chaos for resents a staggering growth of 248% YoY. Taiwan, Korea and Southeast Asia small changes have a big impact. Machin- manufacturing. The just-in-time model has are also expected to register record high investments in 2022. In the Amer- ery investment is capital intensive. Some struggled; container prices are 8- to 9 times icas, the report shows fab equipment spending peaking at $9.8 billion by sectors, such as agricultural, semiconductor pre-pandemic cost in some routes. ce 2023. ce and electronics, and textile machinery are - Edited from a SEMI press release by CFE Media. SEMI is a CFE Media and performing strongly. Other sectors, such as - Edited from an Interact Analysis press Technology content partner. aerospace, are having a much harder time. release by Chris Vavra, web content manager, Regionally, Europe was the worst affect- Control Engineering, CFE Media and Tech- ed by the pandemic, with a 2020 manufac- nology, [email protected]. Interact Anal- turing slump of 7.9% and a 12% slump in ysis is a CFE Media content partner. Manufacturing technology orders rose in 2021 MANUFACTURING TECHNOLOGY orders totaled $436.6 million in January 2022 according to the U.S. Manufacturing Technology Orders (USMTO) report published by The Association for Manufacturing Technology (AMT). January 2022 orders decreased by nearly 27% from December 2021, but increased by 33% from January 2021. The orders were the strongest on record since USMTO began tracking orders. “USMTO typically shows a drop in orders from December to January, and, after December 2021 proved to be the best month on record, we expected to see a substan- tial decrease,” said Douglas K. Woods, president of AMT in a press release. “Recording the best January on record is a welcome sign that the strength of the manufacturing technology market will continue into 2022. Recent demand for production capacity has shifted from sectors producing final consumer goods to ones closer to the raw mate- rial process.” Strong consumer demand through January 2022 drove continued invest- ments in manufacturing technology in all stages of the supply chain. ce - Edited from an AMT press release. control engineering — www.controleng.com |April 2022 15

INSIGHTS TECHNOLOGY UPDATE: ENERGY RECLAMATION Water energy reclamation for process facilities An effective way to reclaim energy and reuse gray effluent. There is an effective way to reclaim energy water elevates water temperatures, originally for a and reuse gray water (clean or partially clean waste- research application. The control sequence for water after a process) from a process that uses elevat- monitoring is highlighted. ed water temperatures for a research application. In addition to being placed back into the process water —Erik Eaves, Facility owners are striving to make their build- system, the heat can also be distributed to other hot ing systems as energy efficient as possible and water systems in the building. Where the specific McClure Engineering a process derived from a research application application permits, the gray water is reclaimed and may help. Improving energy efficiency reduces reused in the process research water loop. operating costs and delivers a positive impact on the environment and carbon footprint. The perception System: Wastewater heat, regarding process and/or research systems often is water reclamation there are no opportunities to design a system that can save energy relative to the baseline needed for a spe- Typically, gray water from the research application cific research application. is sent to sewer after being cooled to below 140 °F. A For some process water systems that use a large process research application that uses significant ener- volume of water and a significant amount of energy gy and large volumes of water presents a great oppor- to add heat, facility managers can reclaim the energy tunity for the designer to create a process to return from the process and in some cases, even reclaim the significant resources back into the building systems. The concept is most applicable for systems heating Hot water energy recovery system Recclaimed energy water in the 160 to 200 °F range. to the existing hot Incoming 180oF After hot process water is used for the research grey water water system application, the gray water can be drained to a col- lection sump or insulated tank rather than being Grey water P-1 CV-1 sent to the sewer. As the water is collected, assum- sump ing sufficient incoming flow, the float will activate Redundant Heating and start the process of reclaiming the energy. The pumps water heat water is pumped through the system where the exchanger process of reclaiming the energy and water occurs. HX-1 The first stage downstream of the pump is a “water to water” heat exchanger where approximate- P-2 Water is either cooled ly 180 °F effluent heat is exchanged indirectly with then sent to sewer or the building potable hot water system, other heat- Heat returned to the process ing hot water systems in the building, or the pro- exchanger cess loop makeup. Multiple heat exchangers can water system be arranged in a series depending on priority and HX-2 expected usage. The gray water is routed back to the CV-3 process water loop make-up to be reused for pro- Heat exchanger to reject heat cess research. Since the water temperature is elevat- so the grey water is < 140oF CV-2 ed even after the heat exchanger, the remaining heat energy is returned to the process loop. prior to sending to sewer Make up water to non-potable hot water Locating the water-to-water heat exchang- Standpipe er in the first position downstream of the pump drain heaters for re-use ensures the maximum reclaim efficiency. When FIGURE 1: A custom sequence of operations must be developed and implemented to control and monitor this process. Diagram, image courtesy: McClure Engineering |16 April 2022 control engineering — www.controleng.com

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the research processes go inactive for a period and water loop. The application can still hot water is no longer needed for that application, work if the water needs to be treated reclaimed energy can still be directed to the other prior to being reintroduced into the hot water needs in the building. system, but the energy savings may be reduced and the payback period When there is not enough load on the reclaim extended. system, the water is cooled and ejected to the sewer. The temperature is monitored to verify it is less than Payback, energy savings FIGURE 2: For some pro- 140 °F before being drained/pumped to the sanitary An energy savings model cess water systems, facility sewer. If the effluent temperature is greater than 140 managers can reclaim the °F, a heat exchanger reduces water temperature prior should be developed for each spe- energy from the process and to release to sanitary sewer. The Figure 1 diagram of cific case to verify the energy sav- in some cases, even reclaim the process is explained below. ings and payback. From those the effluent. results, the designer, in collabora- Control sequence for monitoring tion with the owner, can determine For this system to work efficiently, a custom if the system is an economically viable solution for their applica- sequence of operations must be developed and tion. Even if the system requires implemented to control and monitor this process. water treatment (water softeners, etc.), the system A sample sequence of operations follows: could still show a viable payback for building man- agement. Many building owners will approve this 1. The water from the process is drained to a type of project when they find the payback on ener- sump where the pumps (in diagram, “P-1” and gy savings and water reclaim is a couple of years or “P-2”) are energized when the water level activates less. Typically, the larger the system becomes, the the float in the sump. The water is then pumped more opportunity there is for quicker payback times. through the system. Leadership in Energy uOnline 2. When the process gray water from the sump and Environmental Design is greater than 140 °F for more than 15 minutes, controleng.com the control valve (label “CV-1”) opens to enable the LEED is a great system to encourage the design/ heat exchanger (for building potable water, HX-1). construction of more sustainable buildings. As KEYWORDS: process The control valve remains open if the temperature more buildings move toward LEED certification, manufacturing, wastewater of the gray supply water is 140F or greater. this energy/water reclaim system can help achieve points within the LEED rating system. The energy LEARNING OBJECTIVES 3. After the gray water passes through the heat savings and design can qualify for “energy savings” Process water system exchanger (HX-1), it is diverted back to the pro- or “innovation” LEED points. facility managers can cess loop where it is heated and used again for pro- reclaim the energy from the cess water research. The control valve to release the Process water systems for research no longer process and in some cases, water back into the existing gray water loop is open need to be a large energy/water drain for a facili- even reclaim the effluent (CV-2). The control valve for the sanitary branch ty. Innovative solutions can save money and help itself. (CV-3) shall remain closed. the environment at the same time. In addition, the payback on these types of systems is often reason- An energy payback model 4. When the system sees a drop in temperature of able. Thus, the decision to install is often econom- helps show what is being less than 140 °F for more than 15 minutes, the heat ically feasible and sound. As many companies start saved and provide an idea exchanger control valve (CV-1) closes. The gray water to set carbon-neutral goals, energy/water recovery of the return on investment shall continue to return to the gray water process loop. systems will continue to become more relevant and (ROI) for the project. When the gray water needs to drain to sanitary in lieu viable for designers and facility managers. ce of being reintroduced to the process water research LEED certification can help loop, CV-2 closes and CV-3 opens. Erik Eaves, PE, is a principal at McClure Engineer- process manufacturers help ing. Edited by Chris Vavra, web content manager, facility managers focus on 5. If the water temperature going to sewer is Control Engineering, CFE Media and Technology, where to reduce energy. greater than 140 °F, the heat exchanger (HX-2) is [email protected]. energized to shed the heat load. ONLINE See more on process For this application, the process water used in manufacturing at research remained “clean,” so no water treatment was needed before being introduced back into the process https://www. controleng.com/ process-manufacturing/ control engineering — www.controleng.com |April 2022 17

The Control Engineers Guide to Selecting Edge Devices John S. Rinaldi | Owner, Real Time Automation® Some proponents of Industry 4.0 and Smart Manufacturing are urging a radical restructuring of manufacturing control systems, tools and techniques. They are insisting that a new breed of machine controller be adopted. A controller that provides not only basic machine control but one that supports 3rd party software applications, Cloud analytics, autonomous process control and more. A controller that not only supports Industry 4.0 applications but simplifies the communications for moving the data across the factory floor. This will not happen overnight and and most will agree but some will argue it won’t happen at all. What we do know is today’s legacy machinery and often decrepit control systems won’t be going away quickly. In the meantime, edge data collection devices will be used to harvest data from legacy machine control systems to make data available to Smart Manufacturing applications running in the Enterprise and the Cloud. It is important that before selecting and implementing these kinds of edge devices, operations and control engineers carefully evaluate all the components of the systems they will use before deploying any edge computing or edge data collection device. There are four key areas of concern: Download the paper at: https://bit.ly/36rP7Di ฀ •฀ The Platforms needed to process the data ฀ •฀ The Security Systems that will protect production networks input #10 at www.controleng.com/information ฀ •฀ The Data Models necessary to organize and simplify the ingested data into the advanced Smart Manufacturing applications ฀ •฀ The Protocols that will make that data available to the platforms processing the data This paper examines each of these areas and identifies a total of ten key recommendations that an operations or control engineer should consider before selecting and implementing edge devices. For detailed information on moving data from a PLC or other network, call 1-800-249-1612, email us at [email protected] or visit our website.

INSIGHTS TECHNOLOGY UPDATE Advancing flue-gas flow monitoring Get help with selecting the suitable flowmeter for optimum performance for the flue-gas (stack gas) measurement. Manish Patel, FIGURE 1: A differential pressure-based flow- meter with aerofoil, annubar or pitot-tube Leomi Instruments Pvt. Ltd. measurement restricts the flow path and measures differential pressure across prima- Efficient operation of today’s power plant ry flow elements to derive a volumetric flow largely depends upon accurate and repeat- rate. With additional continuous pressure able measurement of primary and sec- and temperature (instantaneous density) ondary airflow to coal mills, flue gas compensation, mass flow rate can be derived. recirculation flow, overfire airflow, airflow to Images courtesy: Leomi Instruments Pvt. Ltd. individual burners and other areas. Selecting the right flowmeter for flue gas or stack gas emission trol boards for environmental pollution control. It is flow rate measurement is critical. Such measure- important to measure the composition and concentra- ments are important for quantifying emissions tion of polluting gases and mass flow rates to arrive at using continuous emissions monitoring systems the total emission discharge in the environment. Flue (CEMS) for environmental reporting for govern- gas flow rate measurement is imperative for: ment authorities for pollution control. Composition of flue-gas combustion • Optimizing electrostatic precipitator (ESP) Flue gases are gases emitted due to the combus- performance by maintaining design parame- tion process due to heating of fuel (liquid or solid or gaseous) and air with a stoichiometric ratio in ters, such as specific collection area, gas veloc- boiler heating and process furnaces. Flue gas pro- duction from combustion mainly consist of: ity, and treatment time in the controlled ESP. uOnline • Nitrogen (N2) • Indicates early warning for preheater • Carbon monoxide (CO) • Carbon dioxide (CO2) condenser failures controleng.com • Traces of sulphur dioxide (SO2) • Nitrogen oxides (NO, NO2) • Help regulate harmful pollutants, KEYWORDS: Flue-gas • Suspended particulate matter (SPM) dust emission controls measurement flowmeter • Moisture. technologies • Useful info on optimizing mass balance Flue gases are gases emitted due to combustion • Simple design to operate; helps in LEARNING OBJECTIVES process due to heating of fuel (liquid or solid or gas- Understand why is flue-gas eous) and air in thermal power plants, steel plants and energy conservation flow measurement is so foundries, cement production plants, chemical and • Predictive and preventive measures for opti- important. fertilizer production process plant, many other indus- trial, commercial, and other facilities. mizing process efficiency and reducing harmful Learn where the flue- emissions in the environment. gas flow rate should be Why is flow measurement so important? monitored. Most flue gases emission contains air pollutants Process conditions of flue gas in stack Explore flue-gas flow harmful to human health. CEMS are mandatory for Process engineers design the lowest possible heat monitoring technologies, providing reporting to state and central pollution con- flowmeters and selection loss into the environment for better power plant advice. thermal efficiency. Flue gas process conditions with optimum design often have below process parame- CONSIDER THIS ters such as: Have you examined, lately, where your facilities measure flue gas and with what? • Composition, where flue gas has moderate ONLINE dust/fly-ash particles, as in a coal-fired power New Products and Services generation or steam generating plant for Engineers from Control or process. Engineering and CFE Media and Technology: www.controleng.com/NPE control engineering — www.controleng.com |April 2022 19

INSIGHTS TECHNOLOGY UPDATE • Process temperature of 130 to 180⁰C. gas desulfurization plant (wet FGD/dry FGD ) in a • Process velocity: Recommended approximately thermal power plant; in the process stack in chem- ical production, fertilizer and steel plants; and in 12 to 20 meters per second (m/s). process venting systems. Where should flow rate be monitored? Technologies, selection advice To get optimum efficiency, flue gas can be mon- Main technologies flue gas flow monitoring are dif- itored at the chimney or stack near to the point of ferential-pressure (DP)-based flowmeter (with aer- sampling for lab analysis; at the inlet of the flue ofoil, annubar or pitot-tube designs), non-contact ultrasonic flowmeter and an insertion thermal mass FIGURE 2: Thermal mass (cal- flowmeter. A process instrumentation engineer’s task orimetric) flow meters work is identifying which flowmeter will be the most suit- on the physical principle of able technology for the application. Below are import- thermal dispersion from a ant factors to be considered and evaluated with heated element to the ambient comparing technologies for optimum selections: medium (air or gases). This is affected by the velocity, densi- • Duct or pipe dimension ty (temperature and pressure), • Insulation thickness, if any and by the characteristic of • Process conditions such as flow rate, the medium. The amount of needed energy is a function of pressure, temperature, density, viscosity, the temperature difference ∆T dirt and moisture, etc. and the mass flow. • Installation conditions, such as horizontal, vertical and available straight lengths, time FIGURE 3: Efficient operation of today’s power and effort, etc. plant depends largely upon accurate and repeat- • Accuracy and repeatability needed able measurement of primary and secondary • Process turndown ratio needed airflow to coal mills, flue gas recirculation flow, • Budgeted price. overfire airflow, airflow to individual burners, and other areas. Based on the above factors process engineers must understand the working principles, positive and negative attributes of different flow measurement technologies and selection possibilities. Knowing technologies help with flowmeter selection. Help with selecting a DP flowmeter The working principle: A differential pres- sure-based flowmeter with aerofoil, annubar or pitot-tube measurement restricts the flow path and measures differential pressure across primary flow elements to derive a volumetric flow rate (Figure 1). With additional continuous pressure and tem- perature (instantaneous density) compensation, mass flow rate can be derived. Pros: • Established standard BS-1042/ISO 5167 for volumetric flow measurement • Suitable up to 5 m or higher • Rugged designed for any process conditions of industries |20 April 2022 control engineering — www.controleng.com

For MQTT smarter is better Making MQTT smarter is better when it comes to OT/IT and Industrial IoT applications. These complex systems are more demanding than just connecting field devices to a central SCADA system. As a lightweight transport protocol, MQTT specifies that messages are simply carried— not read. But what if we gave an MQTT broker the ability to parse the messages it carries? It could then handle messages more intelligently. On large systems data may come from a wide variety of MQTT devices, each with its own message format. A smart broker that parses messages can convert these to a common message representation and make that available to all clients. With protocol conversion capabilities it could also act as a gateway for OPC and Modbus data to any MQTT client or cloud service. In a real-time industrial system, data consistency is critical. Data that’s stale or out of correct time sequence can lead to incorrect decisions. Any disconnects or network irregularities must be known. A smart MQTT Broker with the ability to parse and queue messages, and to relay data quality information, would ensure that the client stays as synchronized as possible with the physical system in real time. The recommended approach for connecting OT and IT systems is by using a DMZ. Passing data through a DMZ is problematic for MQTT, since it requires two or more servers, linked in a daisy chain. The QoS guarantees in MQTT cannot propagate through the chain, making data at the ends unreliable. A well-designed smart MQTT broker can be used as middleware to convert the MQTT message into a different format, pass it over the network, and convert it back to MQTT or another protocol at its destination. These are a few ways that a smart broker can make MQTT better, especially for large IoT and OT/IT systems: collecting data from diverse sources, ensuring data consistency, and providing secure, robust connections across multiple networks and DMZs. Download the paper at: https://skkynet.com/forMQTT input #11 at www.controleng.com/information [email protected]฀•฀skkynet.com

INSIGHTS TECHNOLOGY UPDATE ‘Insertion • Any orientation is possible the temperature difference (∆T) and the mass flow thermal mass • Highly repeatable (Figure 2). flowmeters can • Site calibration is easy. be a good and Cons: Gas flowing through two resistance tempera- less expensive ture detector sensors (RTD) Pt-100, one reference alternative to a • Higher pressure drop (Tref) and another heater (Th). The tempera- ’DP flowmeter. • Needs periodic maintenance ture difference (over-temperature) ∆t between • Lower accuracy 3% full-scale deflection the reference sensor (medium temperature) and the heater sensor is controlled constantly. As per (FSD) and may drift over time King’s Law, the higher the mass flow rate, the • Lower turn-down ratio 4:1 higher the cooling effect of the heater sensor, thus higher the power required to maintain the differ- (range of accurate fluid measurement) ential temperature constant. Therefore, the heater • Lower flow sensitivity power is proportional to the gas mass flow rate. • Susceptible to clogging Pros: • High wear factor • High installation cost. • Works on constant calorimetric temperature anemometry (Thermal dispersion) Non-contact ultrasonic flowmeter Working principle: A non-contact ultrasonic • Pipe sizes suitable 15 mm to 10 m • Insertion is rugged and works up to 400⁰C flowmeter measures volumetric flow rate consisting of a pair of ultrasonic trans-receiver that transmits and 16 bar (232.06 psi) or more and receives ultrasonic pulses across the flue gas • Any orientation possible path in both directions, resulting in a transit time • Better accuracy < ±2%RD of mass flow rate (time difference) proportional to stack gas velocity. • Highest turndown ratio 100:1 or better It depends mainly on the sound velocity of the gas. • Adjustable and versatile Pros: • Lowest pressure drop • Low cost of ownership against other flow • Derives volumetric flow rate by ultrasonic beam transit-time measurement technology • Online thermal conductivity compensation • Used for pipe diameter up to 10 m Cons: • Suitable for temperature up to 450⁰C • Horizontal or vertical orientation is possible • Mechanically vulnerable to damage • Turn-down ratio better than 100:1. • Flow straightener recommended Cons: • Affected by high moisture (>10% volume), dirt/ • Gas must be dry and clean dust. Needs periodic cleaning or system purging. • Accuracy up to ±1.5 to 3% Rd (Rd or reading Flue-gas (stack gas) measurements is closeness to the value as a percentage of the Check with manufacturers for latest design value) and repeatability ±1% • High initial cost improvements or configurations that may eliminate • Need good technical knowledge some disadvantages. Insertion thermal mass flowme- when installing ters are preferable for stack diameter up to 8 m or less • Not suitable for pipes with inner lining with moderate wet or dust load conditions with a suit- • Drift due to change in flue-gas sound velocity. able purging system. Insertion thermal mass flowme- ters can be a good and less expensive alternative to a Insertion thermal mass flowmeter DP-type flowmeter. Ultrasonic gas flow meters can be Working principle: Thermal mass (calorimet- a good alternative for large stack diameters above 8 m compared to DP and thermal flowmeters. ce ric) flowmeters work on the physical principle of thermal dispersion from a heated element to the Manish Patel is director, Leomi Instruments Pvt. ambient medium (such as air or gases). This is Ltd. Edited by Mark T. Hoske, content manager, affected by the velocity, density (temperature and Control Engineering, CFE Media and Technology, pressure), and by the characteristic of the medi- [email protected]. um. The amount of needed energy is a function of |22 April 2022 control engineering — www.controleng.com

EDUCATION for ENGINEERS ROBOTICS ONLINE COURSE: PLCs How to specify motors SPRING EDITION SPRING EDITION for more efficient HVAC systems Sponsored by Sponsored by One (1) certified professional development hour (PDH) available for all attendees. Register today! www.controleng.com/webcasts | www.controleng.com/research | www.controleng.com/ebooks | cfeedu.cfemedia.com ONLINE COURSE: RESEARCH: ONLINE COURSE: Take a cost-productive Career and Salary What to know when repairing electric approach to OT Survey, 2021 cybersecurity motors One (1) certified professional One (1) certified professional development hour (PDH) available development hour (PDH) available for all attendees. for all attendees. Course runs until April 27, 2022 Course runs until Aug. 12 2022

INSIGHTS NEWS Three robotic automation trends in 2022 uWITH DEMAND for robots growing as TREND #1: The EV revolu- ditionally associated with e-commerce and companies in multiple sectors look for tion changes automotive consumer goods, but now required in auto- new ways to enhance their productivi- manufacturing motive to ensure the necessary flexibility to ty and competitiveness post-pandemic, meet varying levels of demand.” ABB has compiled a set of three growth With many countries restricting and predictions that focus on key trends phasing out the production of combustion Another major shift will see battery driving demand for robots in the com- engine vehicles over the next decade, the manufacturing brought closer to vehi- ing year. race towards electric cars has accelerat- cle assembly, to meet sustainability and ed. Manufacturers and their supply chains regional requirements, which in most \"The pandemic accelerated far-reach- must tackle the complexity of diversi- cases requires all-new facilities. ing global mega trends – from labor fying into electric vehicles (EVs) along- shortages and supply chain uncertain- side combustion-engine vehicles, to meet TREND #2: E-commerce ty, to the individualized consumer and varying regulatory frameworks governing accelerates growing pressure to operate sustainably EV adoption across the globe. The speed and resiliently – leading new businesses and added flexibility needed will see new Consumer behavior and expectations to look to robotic automation,” said Marc and established manufacturers move away are driving companies to find new ways Segura, ABB’s newly appointed robotics from traditional linear manufacturing, to satisfy demand, developing new chan- division president. “As technology opens towards modular, flexible production. nels through omni-channel retailing and new opportunities for meeting custom- adapting their production lines and distri- er demands, new trends will continue to Segura said, “EV is not about a change bution processes to enable personalization emerge that will further drive demand in only in the powertrain, but a larger trans- of both products and delivery. Fulfilling areas where robots have traditionally not formation to a digitized car. This transi- these requirements has seen thousands been used.” tion will also see the growing uptake of of robots installed worldwide where they robots in combination with other technol- were not used just five years ago, and this Based on customer conversations, ogies, including autonomous mobile robots rapid rate of automation will continue in market research and a global survey of (AMR’s). This will enable manufacturers to 2022 driven by a combination of consum- 250 companies across multiple industries, optimize the delivery of components across er trends and a growing shortage of labor. ABB has identified three key trends that facilities and enable integrated scalable, will shape the demand for robots in 2022. modular production cells – methods tra- “This trend will see the growth of light- er, smaller robotic applications, enabling the expansion of automation into new areas of warehousing and distribution operations. As Artificial Intelligence in robotics matures and learning robots become mainstream, expect to see these technologies deployed alongside AMR technologies, orchestrated and managed by intelligent software to pro- vide enhanced flexibility, speed and efficien- cy,” Segura continued. ABB has compiled a set of three growth predictions that focus on key trends driving TREND #3: More robots, in more demand for robots in the coming year. Courtesy: ABB places, more worker skills Robots and collaborative robots (cobots) also are helping to remove many of the barriers previously preventing com- panies from investing in robots. This is seeing an acceleration of robots in gener- al industry and small and medium-sized enterprises as companies seek new ways |24 April 2022 control engineering — www.controleng.com

Digital edition? Click on headlines for more details. See news daily at www.controleng.com to automate different tasks. Turn wastewater into a valuable resource Segura said, “As we look beyond 2022, by optimizing electrical processes we see an ever-greater emphasis on connec- A STANFORD UNIVERSITY STUDY, study is paving the way to mining sewage tivity and data acquisition as key enablers for valuable materials used in fertilizers and batteries that could someday power of future manufacturing. Data collected smartphones and airplanes. The analysis reveals how to optimize electrical pro- from intelligently automated processes will cesses for transforming sulfur pollution, and could help lead to affordable, renew- be analyzed by producers to make more able energy-powered wastewater treatment that creates drinkable water. informed decisions. At the same time, more advanced and responsive simulation and A better solution with a better process programming software tools, will cover the entire life cycle of robotic applications – As fresh water supplies dwindle, particularly in arid regions, focus has inten- from commissioning to onstream produc- sified on developing technologies that convert wastewater to drinkable water. tivity – using AR and VR tools to simplify Membrane processes that use anaerobic or oxygen-free environments to filter automation for customers.” wastewater are particularly promising because they require relatively little energy. However, these processes produce sulfide, a compound that can be toxic, corro- The enhanced ability of robots to work sive and malodorous. Strategies for dealing with that problem, such as chemical directly alongside humans, share tasks oxidation or the use of certain chemicals to convert the sulfur into separable sol- and learn through AI is also making it ids, can generate byproducts and drive chemical reactions that corrode pipes and easier for companies to adopt intelligent make it harder to disinfect the water. automation in new environments, such as construction, healthcare laboratories and A solution for dealing with anaerobic filtration’s sulfide output lies in converting restaurants and retail. the sulfide to chemicals used in fertilizer and cathode material for lithium-sulfur bat- teries, but the mechanisms for doing so are still not well understood. So, Tarpeh and In a future with a high prevalence of his colleagues set out to elucidate a cost-effective approach that would create no robots in workplaces, engineers and staff chemical byproducts. will need to be retrained and more robotic training will be demanded in schools, col- The researchers focused on electrochemical sulfur oxidation, which requires leges and universities, for the skills to pro- low energy input and enables fine-tuned control of final sulfur products. If it gram, operate and maintain robots for an worked effectively, the process could be powered by renewable energy and adapt- automated future. ed to treat wastewater collected from individual buildings or entire cities. Using scanning electrochemical microscopy allowed the researchers to quanti- A decade of robotic expansion fy the rates of each step of electrochemical sulfur oxidation along with the types The trends outlined for 2022 are the and amounts of products formed. They identified the main chemical barriers to sulfur recovery, including electrode fouling and which intermediates are hard- latest chapter in the ongoing transforma- est to convert. They found, among other things, that varying operating parame- tion of robotic automation which is see- ters, such as the reactor voltage, could facilitate low-energy sulfur recovery from ing a rapid acceleration and adoption of wastewater. robots across industry. Balancing energy, pollutant removal, resource recovery “While automation has always been about productivity and quality – scaling up, These and other insights clarified trade-offs between energy efficiency, sul- doing more – the shifts we’re witnessing fide removal, sulfate production and time. With them, the researchers outlined a today (the greatest in a generation) mean framework to inform the design of future electrochemical sulfide oxidation pro- that flexibility and simplicity are key to cesses that balance energy input, pollutant removal and resource recovery. Look- success,” Segura said. “Robotic automation ing toward the future, the sulfur recovery technology could also be combined is a vital enabler of this flexibility.” ce with other techniques, such as recovery of nitrogen from wastewater to produce ammonium sulfate fertilizer. The Codiga Resource Recovery Center, a pilot-scale - Edited from an ABB press release by CFE treatment plant on Stanford’s campus, will likely play a large role in accelerating Media and Technology. See more Control future design and implementation of these approaches. Engineering robotics stories. Rob Jordan, Stanford University. Edited by Chris Vavra, web content manager, control engineering — www.controleng.com Control Engineering, CFE Media and Technology, [email protected]. |April 2022 25

INSIGHTS NEWS Quantum computing project launched in Germany uFRAUNHOFER IPMS is part of the newly launched German infrastructure to enable scalable quantum processors that build funded project QSolid (Quantum Computer in the solid state). on the achievements and advantages of silicon-based semicon- The project centers on quantum bits – or qubits for short – of ductor manufacturing. This concerns, for example, manufactur- very high quality, i.e. with a low error rate. The quantum com- ing processes like deposition and nanopatterning or wafer-scale puter will be integrated into Forschungszentrum Jülich’s super- electrical characterization. Together with Global Foundaries and computing infrastructure at an early Fraunhofer IZM-ASSID, an interpos- stage and will contain several next-gen- ‘The system will contain er technology will be developed focus- eration superconducting quantum ing on high density superconducting processors, including a “moonshot” quantum processors based on interconnects and thermal decoupling system that has been proven to exceed through advanced packaging. the computing power of convention- next-generation superconducting To achieve the ambitious goal of an al computers. The first demonstrator independent quantum computer manu- will go into operation in mid-2024, and ’circuits with a reduced error rate. factured in Germany, QSolid is bring- will make it possible to test applica- ing together 25 research institutions, tions as well as benchmarks for indus- companies, and start-ups from across try standards. the country. The research consortium coordinated by Forschun- Fraunhofer IPMS’ Center Nanelectronic Technologies con- gszentrum Jülich is the largest of its kind in Germany. Together, tributes a 4000 m² clean room and its expertise in state-of-the- the project partners aim to pave the way for commercialization and art, industry-compatible CMOS semiconductor fabrication on develop a comprehensive ecosystem for a demonstrator based on 300 mm wafer standard. \"We intend to use our know-how and superconducting qubits, which will be made accessible to external users via the Jülich UNified Infrastructure for Quantum computing (JUNIQ) and tailored to their individual needs. The partners aim to develop a system containing various quantum processors based on next-generation superconduct- ing circuits with a reduced error rate. This approach is regarded F85RN as cutting-edge by the international community and is also used by companies such as Google, IBM, and Intel. Important prelimi- Fiber Optic Sensor nary work to help achieve the project goals has already been car- of Excellent Operability ried out. Results from the European flagship project OpenSuperQ and the collaborative projects DAQC and GeQcos, which were launched in 2021, will be incorporated into QSolid’s activities. ce - Edited from a Fraunhofer IPMS press release by CFE Media. A multi-function sensor Headlines Online See also pages 7, 8. with Dual Display Top 5 Control Engineering articles March 14-20, 2022 Toll Free: 1-877-371-2727 | Email: [email protected] | Web: www.takex.com Most-viewed articles included stories on Engineers’ Choice winners, tuning a PM motor, maintenance operations, process control systems and more. input #12 at www.controleng.com/information System integration group announces new members The Control System Integrators Association (CSIA) welcomed 15 integrator members and eight partner members to their ranks. World events create disruptions in motors and drives There are several factors in crucial areas of the motor and drive supply chain to note as the Russian invasion of Ukraine continues. Helping humans understand robots Researchers from MIT and Harvard suggest that applying theories from cognitive science and educational psychology to the area of human-robot interaction can help humans build more accurate mental models of their robot collaborators. |26 April 2022 control engineering

INSIGHTS THINK AGAIN Automation, robotics, AI, ransomware Applying automation, robotics, artificial intelligence (AI) Mark T. Hoske may be easier than you think. Preventing a ransomware attack may be more difficult, as explained at the A3 Business Forum in February. Control Engineering A utomation, robotics, artificial intel- Deep learning applications, ligence (AI), and ransomware were resolving worker shortages among topics at the A3 Business Forum, Jan. 31 to Feb. 2. (For advice from other Deba Sen, president, abrasive systems division, Association for Advancing Automation (A3) con- 3M, said the company is bringing in partners to help ference speakers, see “Robotics, motion control, with deep-learning application expertise. COVID- machine vision, AI.”) 19 brought 15 years of technology investments in 5 months, she said. It’s also important to look at what Integrate automation, use robotics to help medium and small manufacturers need since they are humans, make AI scalable, and don’t think for a the majority of U.S. manufacturing output. minute cybersecurity or physical security doesn’t need attention. Also, below, see upcoming confer- Greg Smith, president, Industrial Automa- ences and training opportunities. tion Group, Teradyne (includes Universal Robots, Mobile Industrial Robots (MiR), AutoGuide Mobile Applying robotics, artificial Robots and Energid), continues to see a work- intelligence (AI) in manufacturing er shortage. Smith hoped to help resolve worker shortages with safe and easy-to-use collaborative Oli Qirko, senior vice president and general robotics and AI to solve customer problems. manager, North America, Cambridge Consultants, said clients seek help installing automation to get The era of finding cheap labor is gone, Smith said, fast solutions to help with severe labor shortages. adding automation and AI can provide more sustain- Applications need to be scalable and work with cur- able results. “People make lousy robots, and robots rent systems and minimize disruptions, she said. Interoperability and communication are key. Many OLI QIRKO, senior vice president and general uOnline people want to work with robots, given the chance, manager, North America, Cambridge Consultants, said Qirko. It’s an exciting time for robotics with a and SHANE DITTRICH, co-founder of the House of controleng.com lot of investments and many startups. Design Robotics, each offered automation applica- tion advice at the A3 Business Forum in February. CONSIDER THIS Shane Dittrich, co-founder of the House of Images courtesy: Mark T. Hoske, Control Engineer- Are you making and helping Design robotics, began as a system integrator. He ing, CFE Media and Technology others make automation discussed challenges applying automation to truss investments now? building, difficult because of the wide variabil- ity of wood quality. When working with custom- ONLINE ers, ensure they’re ready for the level of automation www.automate.org sought, Dittrich suggested, letting humans do what humans can and allow automation to do the rest. www.controleng.com/ Automation providers need to provide more open- discrete-manufacturing/ source, easier to integrate and communicate with devices and systems, he added. control engineering — www.controleng.com |April 2022 27

INSIGHTS THINK AGAIN DEBA SEN, president, Abrasive Systems Division, 3M; RASHMI MISRA, general with abstraction layers, hardware, management and manager AI, mixed reality and silicon platforms, business development, Micro- application inputs. Software tools help training to soft; GREG SMITH, president, Industrial Automation Group, Teradyne (includes enhance learning on the job with remote experts, Universal Robots, Mobile Industrial Robots (MiR), AutoGuide Mobile Robots using augmented reality (AR), virtual reality (VR) and Energid); and ANDREW NG, CEO, Landing AI, offered advice about artifi- and mixed reality (MR) to overlay the physi- cial intelligence (AI) use for automation and manufacturing at the A3 Business cal world with digital assets. This helps custom- Forum in February. ers monitor, analyze and fix something while the expert is elsewhere. It is a challenge, Misra said, to make lousy people.” Use optimize objectives and move from a ton of data to something usable, making tools open to all players of AI with automation to democratize every level of capability. “doesn’t make hard things Cybersecurity, ransomware Aiming to demystify ransomware attacks for easy, but it makes impos- manufacturers, Jeremy Dodson, CISO, chief infor- sible things possible.” mation security officer, (left in photo) and Jay Korpi, a principal cybersecurity advisor, both with Enabling technologies NextLink Labs, offered advice. Ransomware is mal- ware that uses encryption to hold data ransom. to help with automation Dodson said he hears many incorrect things JEREMY DODSON, CISO, chief information securi- applications include ROS about ransomware, including that paying once will restore everything. Crooks may or may not restore, ty officer, (left) and JAY KORPI, a principal cyber- (an open-source robotic may or may not seek only one ransom and likely will not remove the malware. Assets also may be security advisor, both with NextLink Labs, each operating system from locked up again after paying once, he warned. offered cybersecurity advice at the A3 Business SwRI) and digital twins Dodson noted six phases of a ransomware attack: Forum in February. to provide realistic emu- 1. The initial access campaign. 2. The actual infection, where systems are lation of what’s going on. breached, often undetected. About AI, Smith observed that once AI starts work- 3. Staging, which is where the hacker ensures ing, then people stop calling it AI. access remains after a system reboot. 4. Internal system scanning for high-value Don’t reject AI Andrew Ng, CEO, Landing AI, said artificial intel- targets (HVTs). 5. Data encryption. ligence has been overhyped in the last 10 years. A rec- 6. Payday, when you’re informed of the breach, ipe that would serve a billion users doesn’t work in industrial automation. Custom AI needs to be applied systems are locked and initial ransom in each factory, Ng said, resolving complex issues with demanded. ingenuity. He warned about buying into the idea that one company has all data and answers. Data centric Korpi said his goal is to help customers go from AI development works on developing carefully curat- that worst possible day to better days. He often ed data sets to get cutting-edge performances. People warns customers about how easy it is for social often apply the wrong set of rules to capture defects. engineering professional to gain physical access to Deep learning can use a different approach by show- systems to plant ransomware, adding, “I have never ing the system a set of images what you’re trying to come across a room I couldn’t talk my way into.” detect. AI is automation on steroids. Dodson gave examples about how they Rashmi Misra, general manager AI, mixed real- accessed (with corporate permission) and ity and silicon platforms, business development, attacked secured areas to plant non-harmful Microsoft, said Microsoft is looking at how it can ransomware to show it could be done. Dodson work with partners to create an ecosystem to help detailed how they gained physical access into a |28 April 2022 control engineering — www.controleng.com

customer’s ultra-secured area twice before the Retrofit solutions can bolt onto ® customer was convinced training was needed. existing systems, measuring electrical use, vibration, heat, and other parame- 3010 Highland Parkway, Suite 325, Downers Grove, Flexible manufacturing; customer needs ters. Healy said adding technology adds IL 60515. 630-571-4070, Fax 630-214-4504 Christoph Schell, chief commercial officer, HP, value, making it easier to justify more investments. Content Specialists/Editorial talked about how the automation revolution in dig- ital manufacturing enables customers to easily find Paper shortage, paper stock Mark T. Hoske, Content Manager professional uses for customized consumer prod- It seems few industries are imper- 630-571-4070, x2227, [email protected] ucts. As president of HP’s 3D printing and digital manufacturing efforts, he noted a huge accelera- vious to supply chain disruptions, but Jack Smith, Content Manager tion of technologies during the last two years, cit- Control Engineering offers apologies, 630-571-4070, x2230, [email protected] ing some estimate of 5 years of digital adoption in anyhow. Some reading this print edition 8 weeks. Must if the investment is expected to stick may find a lower-grade paper stock in Kevin Parker, Senior Contributing Editor, IIoT, OGE past COVID-19. The blur of professional and per- their hands, which was the best we could 630-571-4070, x2228, [email protected] sonal lives has created huge opportunities for busi- do given a paper mill strike in Finland nesses: We're all in the supply chain, Schell said, and continuing supply chain turmoil. Emily Guenther, Director of Interactive Media and opportunities include: 630-571-4070, x2229, [email protected] In person, digital learning 1. Flexibility and performance at the right price Control Engineering is about educa- Amanda Pelliccione, Director of Research point. This included ability to use a credit card 978-302-3463, [email protected] from home to design, test, and print better robot- tion. See specific opportunities for more ic parts, shortening the supply chain from 8 to 10 learning on pages 5, 57 and below. Gary Cohen, Senior Editor weeks to 6 days. [email protected] Automate, June 6-9, Detroit, A3 2. Hyper-customization can disrupt production as www.automate.org Chris Vavra, Web Content Manager the digital twin becomes manufacturing output. [email protected] ARC Forum, June 6-9, Orlan- 3. Sustainable supply chain enables technol- do, ARC Advisory Group, Contributing Content Specialists ogy built with the future in mind: 60% of glob- www.arcweb.com/events/ al consumers are interested in sustainability when arc-industry-forum-orlando Suzanne Gill, Control Engineering Europe the buy. Digital manufacturing ships designs, not [email protected] products. Globally, 1 in 3 list sustainability as most Smart Manufacturing Experience, important when buying. Digital manufacturing June 7-9, Pittsburgh, SME, CESMII, AMT, Ekaterina Kosareva, Control Engineering Russia enables flexibility, speed, affordability and respon- www.smartmanufacturingexperience.com. [email protected] siveness to customer sustainability requirements, Schell said. “Digital twins are our metaverse,” Schell CSIA Executive Conference, Den- Agata Abramczyk, Control Engineering Poland observed. “They’re already here for manufacturing.” ver, June 27-30, www.controlsys.org/ [email protected] events/conference2022 Condition monitoring, more sensors Lukáš Smelík, Control Engineering Czech Republic In a discussion with Control Engineering after IMTS 2022 (AMT) www.imts.com [email protected] and Hannover Messe USA (Hannover the conference, Will Healy III, marketing man- Fairs USA), Sept. 12-17 Aileen Jin, Control Engineering China ager, Americas for Balluff, said he sees more dig- [email protected] italization attention being given to condition https://hannovermesseusa.com monitoring and predictive maintenance. Sen- Vision Show, Oct. 11-13, Boston, A3, Editorial Advisory Board sors used to monitor critical assets make that an www.visionshow.org, co-located with increasingly approachable entry point, he said, Autonomous Mobile Robots & Logis- www.controleng.com/EAB checking critical measurements of pumps, motors, tics Week 2022, A3, Oct. 10-13. Doug Bell, president, InterConnecting Automation, fans and HVAC systems, especially as there are Pack Expo Chicago, Oct. 23-26, www.interconnectingautomation.com fewer maintenance people available. Systems can PMMI, www.packexpointernational.com. get data and notify as needed to protect critical Think again about digital education David Bishop, chairman and a founder systems first, because if those break, no one can with CFE Media and Technology. Matrix Technologies, www.matrixti.com work, such as when pumps fail in a painting facili- www.controleng.com/online-courses ty, and production stops. www.controleng.com/webcasts Daniel E. Capano, senior project manager, Gannett Fleming www.controleng.com/webcasts/past Engineers and Architects, www.gannettfleming.com https://cfeedu.cfemedia.com/pages/ virtual-training-week ce Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com control engineering |April 2022 29 Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com CFE Media and Technology Contributor Guidelines Overview Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. 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ANSWERS COVER: PID TUNING ADVICE James Beall, Emerson The control system is key to optimal loop tuning Leveraging proportional-integral-derivative (PID) tuning tools embedded in automation software helps identify and maintain ideal tuning values, regardless of process changes. uOnline Accounting for pro- Embedded loop-tuning controleng.com cess industry changes tools deliver easier control to ensure consistency KEYWORDS: requires careful con- A wide variety of tools are PID, process optimization, trol loop tuning, and, in more available in the marketplace to control system tuning complex scenarios, can neces- help personnel better tune control sitate advanced process control loops for plant processes, which LEARNING OBJECTIVES strategies. In the process indus- can make selection difficult. The Explore how embedded tries, change is constant in prod- best combination of performance, loop-tuning tools deliver uct composition, production rates cost, and ease of use often comes easier control. and even personnel. Processes are from control loop tuning tools subject to a wide variety of fac- embedded in the control system See how process tors impacting quality and per- itself because integrated loop tun- awareness drives smoother formance. Many plants struggle ing technologies can take advan- process changes. with maintaining enough person- tage of all the configuration data nel to perform loop tuning and already stored in the control sys- Understand embedded advanced control. tem. This helps ensure critical data tuning optimization, interactive loops. Organizations do not need FIGURE 1: Properly tuned control- to adjust staffing and schedules, lers lead to significant operational CONSIDER THIS potentially delaying other critical benefits. Engineering teams can Have you reconsidered work, to monitor and tune control use an embedded toolkit on an strategies for control-loop loops. Many organizations want the control sys- Emerson DeltaV control system to quickly identify optimization? tem, the technology central to process operations, loop dynamics and tune even the most complex loops to be a strategic tool to assist in maintaining prop- in the plant. Images courtesy: Emerson ONLINE er proportional-integral-derivative (PID) tuning. https://www.controleng. is correct from the moment loop tuning is imple- com/control-systems/ Using PID tuning tools integrated into modern mented, with this data automatically synchronized pid-apc/ control systems let process control personnel tune regardless of the changes personnel make to the processes on demand, adapt to process changes process or the control loop. and automate the tuning process for better per- formance and quality. Plants using control-sys- Engineering units, tuning changes, loop tag tem-integrated PID often see significant benefits numbers, process variable scale, and other PID in throughput, energy costs, quality variation, and options are automatically updated and reflected in equipment availability (Figure 1). embedded tuning tools when values change. This |30 April 2022 control engineering — www.controleng.com

FIGURE 2, COVER: A large polymer plant used the loop tuning toolkit embedded in its Emerson DeltaV distributed control system to reduce startup time and increase production rates. With another plant’s control system upgrade, adaptive tuning and control soft- ware embedded in DeltaV enabled controllers to maintain the desired response and reduce variability over the full operating range. reduces the number of person- ‘The control system is a strategic tool to nel needed to maintain loops and assist in maintaining proper proportional- can reduce or eliminate the risk of data entry errors. ’integral-derivative (PID) tuning. When using an external tool, the services needed to maintain process awareness and under- required to copy the control system database, mod- stand when changes impact production. If pro- ify it, and set up replication increase cost, time and cess dynamics change when production variables potential for errors. In contrast, embedded loop change, PID tuning parameters must as well to help tuning tools come already installed in the control ensure optimum performance. system, eliminating duplicate effort. Setting up an integrated system typically requires no more than The most advanced loop tuning tools use pro- the few clicks necessary to activate the software. cess learning to develop reliable process models as closed-loop control is executed. These process On-demand tuning in learning tools run in the background 24/7, iden- action in a power plant tifying process models and comparing against the active model. When process dynamics change and For one power plant where nearly 50% of con- deviate far enough from the existing model to cause trol loops were underperforming, operators found a problem, adaptive tuning systems alert plant per- themselves spending far too much time attend- sonnel to let them know further tuning is required. ing to troublesome loops. The engineering team Operators or engineers can use the interface to used the embedded toolkit on their control system update the tuning parameters based on the new to identify loop dynamics and tune even the most process model. complex loops in the plant. Not only does adaptive tuning keep plants alert Using the process data and configuration details to necessary PID tuning changes without the need gathered and contextualized directly from the con- to commit personnel to manually monitor loop trol system, the team created a structured approach tuning, it also helps operations and process control to the identification of control performance prob- personnel trend process performance. If the adap- lem sources and developed appropriate loop tuning tive tuning software alerts operators to a need for parameters. new tuning too frequently, the team can quickly see something is changing in the process dynamics. Implementing embedded control loop tun- They can then compare parameters of the process ing significantly improved performance across the plant. Better PID tuning improved the plant’s con- trol performance, and processes across the facility experienced gains in throughput, as well as reduc- tions in energy cost and quality variation. Process awareness drives smoother process changes One of the primary factors causing control loop tuning to take up so much time is the manual effort control engineering — www.controleng.com |April 2022 31

ANSWERS COVER: PID TUNING ADVICE model versus current or past state variables to iden- Adaptive control at a gas plant tify patterns and relationships, and to determine In one large gas plant, quality specifications were root causes of these issues. not being met because key control loops overshot ‘An adaptive Embedded tuning at a polymer plant their setpoint or oscillated around it. Operators system was At a large polymer plant, poor control perfor- were forced to frequently intervene to make adjust- used to manage ments, or they kept the loops running in manual the tuning for mance of the reactor temperature control system mode. Not only were process upsets causing alarms, different product led to downtime when the safety system would trip trips, and opening of release valves, but cycling was ’formulas. the reactor (Figure 2). The problem was exacerbat- also shortening the life of the plant’s control valves ed by long reactor startups and frequent product and other equipment. formula changes, which caused long waiting peri- ods for the temperature to stabilize. As part of a control system upgrade, process control personnel implemented adaptive control. Because different product formulas required dif- Using the adaptive tuning and control software ferent tuning, reducing the reactor trips was not as embedded in their new control system, the control- simple as creating a set-and-forget tuning strategy lers maintained the desired response and reduced for the slurry loop. Instead, the team turned to the variability over the full operating range. loop tuning toolkit embedded in the control system to measure the complex process dynamics of the Today, the plant’s loops stay in automatic mode reactor and its coolant systems for different prod- and maintain performance over the entire operat- uct formula groups. Then, an adaptive system was ing range. Flow, temperature and composition are used to manage the tuning for different product more accurately controlled, bringing improvements formulas. in product quality, yield, energy consumption, operator effectiveness and equipment lifespan. The embedded tuning procedure improved pro- cess performance. The operations team reduced Leveraging the power startup and product formula change time by 40% of the control system and increased production rates of some products by as much as 35%. Properly tuned control loops are critical to efficient, productive operations. In today’s envi- 3Fast Facts Tuning interacting loops ronment of personnel shortages and increased per- In some complex processes, manual tuning formance expectations, performing manual PID Using control tuning is no longer an optimal solution. Fortunate- system process data is not enough. In these processes, there is a high ly, the tool at the heart of operations, the plant’s and configuration level of interaction among several PID loops. Or, control system, also contains and manages all the details gathered and in other situations, operators optimize processes data necessary to maintain properly-tuned loops. contextualized, the team: by controlling against an active constraint and try- ing to push those parameters as close as possible to Moreover, the most advanced control systems uCreated a structured the minimum or maximum to achieve peak perfor- already contain the tools needed to unlock the approach to the mance. In these and other complex control envi- value in that data to drive faster and easier PID identification of control ronments, teams typically turn to adaptive process tuning as well as implement advanced control strat- performance problem control. egies to increase performance, even in the most sources. complex environments. Adaptive control uses information from process uDeveloped appropriate learning, which identifies changes in the process By leveraging the robust software and contextu- loop tuning parameters. models in relation to specific state variables. Adap- alized data available in the control system, you can tive control automatically changes the PID tuning help improve quality, yield, and energy consump- uSignificantly improved parameters for multiple regions of a state vari- tion, while freeing up the most knowledgeable per- plant performance. able to maintain the desired loop response, with sonnel to focus on other essential tasks. ce no manual intervention required. Operators work in a more supervisory role, freeing them up for James Beall is a principal process control consultant other tasks. The process is more stable, improving at Emerson Automation Solutions. Edited by Mark T. throughput and helping ensure consistent quality. Hoske, content manager, Control Engineering, CFE Media and Technology, [email protected]. |32 April 2022 control engineering — www.controleng.com

ANSWERS COVER: PID Peter Galan, a retired control software engineer PID-correction-based control system implementation The analog PID controller, still considered as the most powerful, can be modified as a discrete-time control system. Equations and examples follow. W hile dealing with the control system will change abruptly and cause problems. A better FIGURE 1: COVER: synthesis in s-domain is complete- approach is to multiply the regulation error by those Block diagram ly logical as the controlled systems two constants first and only then to accumulate their shows a digital operate continuously (in time), the product. Another improvement can be achieved by closed-loop con- control system implementation is however another using the trapezoidal approximation of integration trol system. All matter. Today, almost all control systems are imple- instead of the rectangular one. diagrams courtesy: mented as digital systems, based either on the micro- Peter Galan, retired processors (microcontrollers), or on the digital How to reduce noise control software signal processors as shown in Figure 1. The derivative member of Equation 2 is a second engineer PID for a discrete-time control system source of problems. In its simple form, this member The analog PID controller, which is still consid- tends to be rather noisy. To reduce noise, you can use more than two (for example four) consecutive sam- ered as the most powerful (Figure 2), can be mod- ples of the regulation error. The result is as if the dif- ified for implementation as a discrete-time control ference of the regulation error went through a tiny system, as it is not difficult to rewrite its differential (4-tap) finite impulse response (FIR) filter. Equation 1 into its difference form (Equation 2) The modified PID formula then appears as the (1) following Equation 3. (2) (3) where u[n] is the actuating value at the present time The difference equation above can be imple- n, e[n] is the regulation error at the time n and e[n- mented in any programming language and for any 1] is the regulation error at the previous sample time, microprocessor/microcontroller. n-1. T is the time period of the sampling. The same time period, T, is used for the processing, that is, for Interrupt service routine the u[n] calculation. Still, there is one open question with regard to the For the practical applications Equation 2 requires sampling/processing period, T. What is the correct certain modifications, beginning with the integra- control process period (frequency), and what does it tion member. The integration member adds each value of the regulation error to a sum and then mul- tiplies this sum by the time constant and by the inte- gral constant. If the value of the time or integral constant suddenly changes (which can happen, espe- cially during the tuning process), the actuating value control engineering — www.controleng.com |April 2022 33

ANSWERS COVER: PID integration is a rectangular (Equation 5) and a trap- ezoidal (Equation 6) approximation. (4) (5) (6) If you express y/x in the z-domain, for the rectan- gular approximation you will get FIGURE 2: PID con- depend on? The control frequency depends only on (7) troller calculates an the time constant of the closed-loop transfer func- actuating value from tion. Remember, this time constant can be an order And this is what you get for the trapezoidal proportional, integral, shorter than the time constant of a controlled sys- approximation: and derivative compo- tem itself. Optimally, you should run the control nents. procedure around 5 to 10 times more often than (8) what is the value of the closed loop time constant, ‘To avoid noise, τ. Immediately, before your control procedure Equations 7 and 8 correspond to the integration all measured starts to run, you should have the latest samples of term, which in the s-domain is expressed as 1/s. So, variables have r[n] and y[n] ready (see Figure 1). if you take the inverse transformation/expression of to be thoroughly the right side of the Equation 7 (expressing s) and ’filtered. The best arrangement is if the control procedure substitute with it each s operator in the Equation 4, is called as an interrupt service routine (ISR) trig- you will get the following transfer function of the gered be the A/D converter providing the y[n] value. PID compensation (in the z-domain): Result of the control procedure calculation, the actu- ating variable u[n] , should be sent out to the D/A (9) converter as soon as possible. Otherwise, the transfer function of the controlled system will be affected by Similarly, if you take the inverse transformation/ transportation delays, which could destroy (make it expression of the right side of the Equation 8 and unstable) the control system. substitute with it each s operator in the Equation 4, you will get the following transfer function of the To avoid the noise, which can always penetrate into PID compensation (in the z-domain): the control system from the outside (for example as the “board” noise caused by electronic parts, mainly (10) switching power supplies), all the measured variables - signals like y[t], have to be thoroughly filtered. They Control system modelling in z-domain should “go through” a proper anti-aliasing filter, with Equation 9/10 can be suitable for modelling of the cut-off frequency well below one half of the sam- pling frequency, 1/T, If, for some reason, they cannot the control systems in z-domain, for example in be filtered by proper analog filters, they should be at Matlab by MathWorks, but cannot be directly imple- least over sampled and filtered digitally. mented by any controller. However, after applying an inverse z-transform to Equation 9, you will get the More on the PID control transfer function following equation Equation 3 is not the only way for the discrete (11) implementation of a PID controller. Another possi- bility is the transformation of a PID control trans- fer function from its s-domain (Equation 4) into z-domain. In practice, there are two ways of such a transformation. Both are derived from a different approximation of a discrete time integration. The most common approximations of the discrete time |34 April 2022 control engineering — www.controleng.com

and an inverse z-transform of Equation 10: (12) FIGURE 3: Second-order canonical IIR filter section Equation 11 and Equation 12 are perfectly suit- The last combination will yield the identical serves as a PID able for implementation on any microprocessor response as Equation 12 The lower the A2 value, controller. (microcontroller) or a digital signal processor. If you keep K1, K2 and K3 as the pre-calculated constants the faster is the control system response. This (instead of variables), the entire control procedure will require three multiplications, four additions and Onlinecan simplify the tuning process, as instead of fre- remembering four previously calculated variables – two regulation errors, e[n-1] and e[n-2], and two actu- quently modifying the KI value (which requires ating variables, u[n-1] and u[n-2] (only for Equation u 12). The e[n] calculation requires one subtraction. re-calculation of the KP and KD values if you want controleng.com Infinite impulse response filters You can go even further in the optimization of to have them optimal, that is, cancelling the con- KEYWORDS: Proportional- trolled system poles) you can set the KI constant integral-derivative, PID, your control procedure. The digital signal processing (and the KP and KD values) once to some reason- advanced process control, industry has very popular recursive filters, so-called able value, for example KI to the 10/(τ1+τ2 ) value APC infinite impulse response (IIR) filters. Usually, they (where τ1 and τ2 are the primary time constants of are implemented as cascaded, second-order filters. the controlled system) and make the final tuning LEARNING OBJECTIVES One such second order filter, often called as “biquad” by the adjustment of the A1 and A2 values. Examine options for use (biquadratic), converted to its canonical form, which of PID in a discrete-time is called Cascade Form II, is shown in Figure 3. Not every PID implementation control system. is satisfactory Implementation of such a biquad requires less Review how to reduce memory space – instead of four variables – delayed While it is always nice to have a choice when any noise, use of the interrupt terms e[n-1], e[n-2], u[n-1] and u[n-2], it is only algorithmic problem has to be implemented, not service routine and more necessary to remember two state variables, every implementation provides satisfactory results. on the PID control transfer The same applies to the described PID control pro- function. d[n-1] and d[n-2]. The canonical IIR filter sec- cedures. All three procedures work nicely on paper, tion is best described by the following two difference but when implemented, problems will occur. Understand control system equations modelling in z-domain, The first Equation 3 implementation requires infinite impulse response (13) more mathematical operations (multiplication, addi- filters and know that not every PID implementation is (14) satisfactory. You have some, though limited choice for the A1 CONSIDER THIS and A2 values selection. However, two rules have to PID implementations can be obeyed: the sum of A1 and A2 values has to be extend beyond process always 1.0, and no value can be greater than 1.0. So, control applications. you can use as the A1 and A2 coefficient, for exam- ple, values like 1.0 and 0, or 0.5 and 0.5, or 0 and 1.0, tions) and remembering more previous results than ONLINE or anything in between. the remaining two, but it provides very smooth https://www.controleng. results. The behavior of Equation 11 is similar. com/control-systems/ pid-apc/ However, implementation of Equation 12 will fail to deliver satisfactory results, as it runs on the 5 RELATED ARTICLES border of stability, and its output will permanently Introduction to artificial oscillate. The Equation 13/14 implementation will neural networks in control work properly, but the A1 coefficient must be kept applications > 0 because otherwise it will behave like the Equa- tion 12 implementation and produce permanent Event-driven applications oscillations. ce for embedded systems: Summary of PDF Peter Galan is a retired control software engineer; Edited by Mark T. Hoske, content manager, Con- Finite-state machine for trol Engineering, CFE Media and Technology, embedded systems [email protected]. Control system improvements: Feed- forward, adaptive, fuzzy control From simulation to computer-aided design of control systems control engineering — www.controleng.com |April 2022 35

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OFFSHORE INFRASTRUCTURE Complexity reduced in floating production storage and offloading vessels Maximize cost efficiencies during construction Floating production storage and brings unique challenges to light. For exam- several global entities. Whether an opera- offloading (FPSO) vessels deliv- ple, it is essential to maintain tight and effi- tor is retrofitting an existing hull or start- er the same functionality as sta- cient construction schedules to ensure that ing from scratch, most hulls are supplied tionary oil & gas platforms while constructing an FPSO remains a more eco- or built within the Asia-Pacific region being able to relocate as economic head- nomically advantageous solution than if (See figure 1) for coordination, shipment, winds or drilling opportunities change. the operator had simply constructed a fixed and delivery of the hull to the location The industry anticipates FPSO deploy- platform instead. where the necessary fluid systems will be ments rising significantly over the next integrated and commissioned. five years. Some forecasts expect growth FPSOs are expected to deliver more in excess of 14% by 2027. For these vessels than 20 years of uninterrupted service, Today's topside applications and pack- to be successful, a few key considerations as maintenance-related dry dockings ages are increasingly specialized. Major impact the construction process, particu- can sink any potential cost efficiencies. capital projects, FPSOs included, com- larly regarding critical fluid system appli- On-board fluid systems must deliver reli- monly involve numerous engineering, cations and packages. able and safe performance throughout procurement, and construction (EPC) this time period. Finally, strict adher- firms from different global regions. EPCs Challenges, considerations ence to industry compliance standards are responsible for equipment for sever- When commissioning an FPSO, owner/ is mandatory. As the oil & gas indus- al critical packages, and successful coor- try seeks to minimize its environmental dination with each of them is essential operators practice the same due diligence impact, FPSOs will operate with the goal throughout the pre-front-end engineer- as for conventional offshore plat- of achieving net-zero in the future. ing and design (pre-FEED) project stage. forms, but the nature of FPSOs Depending on the owner/operator’s avail- Owner/operators coordinate with able resources, this can be a challenge. FIGURE 1. FPSOs contain numerous critical fluid system No one-size-fits-all solution for appli- applications and packages, each of which must deliver cations and packages found on an FPSO long-term reliability across the vessel’s life. exists. Designers must think critically Continued on page 40 oil &gas engineering |April 2022 37

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OFFSHORE INFRASTRUCTURE FIGURE 2. Rotating equip- FIGURE 3. A turret swivel system ment, including pumps, com- provides crucial connection points pressors, and turbines, are between topside and subsea sys- critical to overall operational tems. A well-designed installation reliability. Downtime can lead using permanently installed tube to production shutdowns and can offer a more reliable and lower profit losses maintenance solution. Continued from page 37 Turret swivel systems (Figure 3). FIGURE 4. Sampling sys- These systems connect an FPSO’s top- tems must be properly about priorities, including reservoir char- side and subsea systems, commonly designed to deliver rep- acteristics; FPSO motion while at sea; using long hose lengths to make such resentative samples and hull size and storage capacity; type of connections. However, hoses require allow operators to safely export system; single or twin production frequent maintenance inspections and use the system, maintain trains; and potential redeployment and may only provide a few years of service chain of custody compli- decommissioning. depending on environmental and opera- ance, and make prop tional conditions. Hose-related production A supplier who has an established, losses can lead to millions in costs. Instead, FIGURE 5. CI units must local presence in the many different turret swivel systems can be designed maintain highly accurate regions where resources reside can be a with permanently installed tube and and repeatable chemical boon for the project. People who under- only short jumper hoses for flexibility. dosage into the produc- stand local cultures, languages, and regu- tion process to provide lations can be a significant benefit. Sampling systems (Figure 4). reliable production. Many different sampling processes are Leak-tight performance Taking stock of critical systems required on a typical FPSO. Howev- is essential. Applications on an FPSO essential to er, it is not uncommon for these sampling points to be inconsistent, system-to-system. a significant impact on the vessel’s long- safe, efficient and productive vessel opera- This kind of inconsistency, both in system term performance. Alloy choice is also a tion include: design and operability, can lead to compro- consideration here—higher-quality materi- mised sampling accuracy. Instead, owners/ als that can provide outstanding corrosion Process and analytical instrumenta- operators can specify properly-designed and resistance can be beneficial in the harsh tion. It is not always a guarantee that the intuitive-to-use sampling systems across the conditions where FPSOs operate. OG right expertise will be readily available at entire vessel. a project’s outset to make the right prod- Tommy Jamail Jr. is senior regional con- uct, material, and design choices for effi- Chemical Injection (CI) units struction manager, Asia Pacific, Swagelok Co. cient and effective analytical systems. As (Figure 5). CI units must deliver highly such, overall system design can pose an accurate and repeated chemical doses into 2Fast Facts early challenge. Poor installation practic- production—any lapses in this process can es during hookup and commissioning can compromise reliable production. A typical uFloating production storage and offloading additionally lead to longer project lead CI system may require hundreds of indi- vessels are located near an offshore oil field, times or may result in leakage, emissions, vidual connections. As such, leak-tight per- where oil is processed and stored until it can and safety concerns. formance is a necessity to maintain safety be transferred to a tanker for transport and and protect the environment. Downtime additional refining. Rotating equipment (Figure 2). Pumps, can result in significant losses. compressors, and turbines are essential uThe largest FPSO in the world by capacity is the to an FPSO’s overall reliability. If any of For these applications, in which leak- Egina, weighing in at 220,000 tons with a storage these systems malfunction, the resulting tight connections are so critical, it can be capacity of 2.3 million barrels, the $3 billion downtime can lead to costly shutdowns. beneficial to specify fluid system com- vessel, operated by Total Energies, the $3 billion Dependable mechanical seal support sys- ponents from a single, reliable supplier. vessel is 330 meters long, 61 meters wide and tems—which keep seal fluid clean and Tubes, fittings, and valves that are explicitly 34 meters tall, and is currently moored at the deliver fluids at the right pressure and designed to deliver leak-tightness can make Egina oil field, 200km off the coast of Nigeria. temperature—can contribute to higher reliability. oil &gas engineering |40 April 2022