2|18 The Phoenix Contact customer magazine | June 2018 Fit for the process Data is the new raw material – if the infrastructure is ready
02 Editorial UPDATE 2|18 Stephan Sagebiel, Head of Industry Management Process Technology and Engineering, Phoenix Contact From the terminal into the cloud Dear readers, For a long time, Industrie 4.0 and digitalization were just keywords. A distant reality, but unable to be realized in everyday production and processes. The prospect of being able to create new products using new technology was too daring. And above all, much too complex and expensive. At this year's Achema in Frankfurt we will be proving the opposite to you! Phoenix Contact is focusing not on the refinery of tomorrow, rather on the processing plant of today, with mature structures and components, featuring partly analogue and partly digital technology. We will be giving you a sneak preview in this issue of UPDATE. In doing so, we will follow the measures that are actually necessary on site – we will show concrete possibilities for undertaking necessary modernization measures during ongoing operation, measures which will actually make the systems fit for Industrie 4.0. From the connection of field devices, through innovative and future-oriented wiring, all the way through to the control center, from the use of long-existing field data, through the implementation of analog and digital signposting, all the way through to cloud-based maintenance and the use of augmented reality. How does the fast and cost-effective mass production of products, such as vaccinations, develop from the production of highly specialized products in small quantities, such as in pharmaceutical production and fine chemicals, without the need to construct new large-scale plants? We will also be showing ways towards this, not only at the world's leading trade fair for process technology, but also in a sneak preview in this issue of UPDATE. We look forward to welcoming you to Frankfurt between June 11 and June 15. And your interest in the following pages. Editorial 02 Stephan Sagebiel Guest article Added value instead of an end in itself 03 Digitalization is changing the process industry Trade fair preview Digital with heart and system 06 Phoenix Contact at the Achema 2018 On site Change the winning team 08 The example of a successful control system modernization project Technology 10 Digital push for analog signals The MINI Analog Pro signal conditioner Hunter of hidden treasure 12 GW PL…-BUS modular multiplexer 14 The cloud guarantees sunshine The ProfiCloud and its tasks Not without my tablet 16 WLAN and Maintenance 4.0 Consistently isolated, responsible together 18 Redundancy ensures safety Examining who connects and how 20 Perfect data packet, thanks to the terminal The untapped data hoard 22 How data becomes “big” and valuable Industrie 4.0 and the flu epidemic 24 The advantages of modular automation News 26 Hannover Messe 2018 reaction overview 27 Developing together with Jean Müller 27 Cooperation with M.A.C. System Solutions Find out more with the web code For more information, use the web codes provided in this magazine. Simply enter # and the four-digit number in the search field on our website. Web code: #1234 (example) phoenixcontact.com
UPDATE 2|18 Guest article 03 Added value instead of an end in itself Digitalization is changing the process industry The task of process automation specialists is to create the technical foundation for digitalization. Even if the benefits are not yet precisely defined in many companies, digitalization will permanently change the process industry and process automation. While in the past it was the technicians and engineers who changed processes and sequences based on what was technically possible, the roles today are quite different: under the guiding principle of Industrie 4.0 and the desire for a digital transformation of the business, process automation specialists are called upon today to create the technical basis for digitalization. For the German chemical industry, Industrie 4.0 is significantly more than predictive maintenance. A recent study carried out by the market research company Deloitte for the VCI Chemistry Association shows what will characterize the chemical industry in the future: a circular economy, sustainability, and digitalization. It is no longer just about classic raw material recycling, but about a new self-image within the industry – Chemistry 4.0. For the first time, data has been identified as being a key production material, alongside the classic raw materials and energies. This raw material should be supplied in part by highly digitalized and automated production processes. Data is the raw material for new business models Examining current projects in the chemical industry makes clear why data will be so important for the process industry in the future. One of the prime examples of new business models is digital agriculture: a collaborative network with new providers is evolving from cooperation between companies in the chemical, agricultural machinery, and food processing industries. These are preparing to optimize agricultural production based on the Armin Scheuermann, Editor-in-Chief of the CHEMIE TECHNIK chemistry journal, Hüthig Verlag publishing house In the “Chemistry 4.0” vision of the VCI Chemistry Association, data has been identified as being a key production material, in addition to raw materials and energies
04 Guest article UPDATE 2|18 User Association consider the digitalization of the process industry as being a three-stage process: in the first stage, the systems operated until now as island systems will be connected together. This is followed by the visualization of the data in the second stage, and finally, in the third stage, the control circuit for entire business processes will be closed and this will be permanently optimized with the aid of a digital twin of the system. That is the theory. Those familiar with the industry know that not even the first stage has been realized yet: system interruptions between engineering, commissioning, and subsequent operation, and even the production systems themselves, are still part and parcel of the process today. The process industry is still a long way from end-to-end digitalization. The understanding of roles between users and providers of process automation has changed, however, and will continue to change: the process automation specialists themselves, who were previously reluctant to use new technologies such as fieldbus or wireless communication, and who therefore delayed the development of these technologies, are setting “ It is about a new self- image within the industry – Chemistry 4.0.” the pace today. Communication techniques such as “Ethernet in the field” (key phrase: “Advanced Physical Layer”) and the uniform FDI device description are now being demanded emphatically, and are to form the foundation for far-reaching digitalization. Confrontation within cooperation has long since disappeared: users and automation manufacturers work together on the committees of the German Electrical and Electronic Manufacturers' Association (ZVEI) and NAMUR to develop the automation concepts of the future. The future of process automation: NOA or OPA? In addition to this, new system architectures are developing where the users are the Data always available real-time analysis of weather, soil, plant, and machine data. “Digital farming” is also a key aspect of the $66 billion deal between Bayer and Monsanto. New business models are also emerging at the interface between materials suppliers, machine manufacturers, and users in traditional chemical and plastics manufacturing: the most recent cooperation between the chemical company BASF and the printer manufacturer HP, for example. These two companies want to collaborate on developing and marketing new types of materials for 3D printing. In the pharmaceuticals industry, the trend is also moving toward new business models based on digital information. Thus, the personalization of pharmaceuticals is changing entire production processes and supply chains. New understanding of roles between users and providers The automation specialists in the process industry have already recognized this trend. Their role in the past was to automate and network production processes, and in some cases to connect and optimize them beyond the borders of the factory fence; in future however, they will be looking to control entire value added chains. The experts from the NAMUR
UPDATE 2|18 Guest article 05 driving forces instead. With the NAMUR Open Architecture, NOA, operators are directing the process automation specialists in how they want their systems to be made fit for Industrie 4.0: the existing automation structure should be able to be supplemented with fast-paced IT components via NOA relatively quickly. Thus, the information from additional sensors or unused data from field devices should be transmitted to the cloud without impact, and evaluated by applications there – without first having to laboriously integrate these sensors into the existing control engineering system. NOA differentiates here between core automation and an open system world for monitoring and optimization tasks. The data from the previous automation system is transmitted into the cloud via open interfaces such as OPC UA. The new structure for process automation proposed by Exxon Mobile in the USA, Open Process Automation or OPA, goes even further. Here, the classic pyramid of process automation is being dissolved and a completely open automation model is being strived for: in the systems of the future, hardware and software from any manufacturer will be able to be used and will work together without any problems. Following this idea through to the end, with the OPA structure, the intelligence is transferred completely into the field – the days of the central process control system are over. Consistent engineering and modular automation Even if NAMUR does not go so far in its projections for the future, German process automation specialists agree with their American counterparts and would also like to see the integration of the various automation utilities over the entire life cycle of a system. Thus, for example, future automation systems should be completely configured from the engineering data. With the “Module Type Package” approach, modular process units should be able to be interconnected and integrated into superordinate control technology structures. The desire for modular systems reflects current trends in special chemicals and pharmaceuticals production: to be able to serve volatile markets, the manufacturers must be able to produce small batches in ever shorter times. Classic systems manufacturing approaches are too protracted for this – the engineering process must be simplified. Therefore, the process-related units are to be designed as modules, and connected together flexibly via standardized interfaces. The fact that modular automation is also to be used here is logical and consistent. Process knowledge thanks to new services Users and manufacturers of process automation systems are also working hand in hand on the MTP project. The fact that users are increasingly relying on their suppliers is due to another trend: the ever-reducing levels of staff in engineering technology. The automation suppliers are reacting to this with new services: in the “Operation Centers” set up by the providers, which are similar to control rooms, their engineers support the process operators during the operating phase with optimization measures and engineering tasks. For the automation specialists, these services are not just an additional product, rather they are also the foundation for new business models, because future big data applications in the process industry demand one thing above all else: knowledge of the mechanisms and the procedural context. The NAMUR Open Architecture presented by NAMUR in 2016 enables the existing automation structure to be supple- mented with fast-paced IT components R Open Architecture Board level Management U M A A – N O N Basic automation Field levels
06 Trade fair preview UPDATE 2|18 Digital with heart and system New products, new services, greater expertise – Phoenix Contact demonstrates its range at the Achema 2018 During a visit to the Bad Pyrmont location, Wilfried Grote, Director Industry Management, shows us the heart of the trade fair booth: an imposing large-scale model of a bioethanol plant. The engineer's eyes light up as he tells us about the solutions that Phoenix Contact will present this year. UPDATE: Mr. Grote, what are the highlights this year at the Achema trade fair booth? Wilfried Grote: First of all, we are not only talking about digitalization, our booth itself is also fully networked and is a microcosm of what we offer on a large scale in terms of products and services. We will complete our trade fair reports via iPad, we will demonstrate augmented reality applications directly online, as in a large-scale plant, and, in dialog with our customers, we will also access our product catalogs and websites directly. UPDATE: We are standing in front of a large- scale model, which is to be accommodated in a central area of the trade fair booth. What will this be used to demonstrate? Wilfried Grote: Under the heading “Modernizing processing plants and creating new benefits”, we will be demonstrating our industry-specific expertise with various exhibits. As an eye- catcher, we use this model of a processing plant for the manufacture of bioethanol, in which we demonstrate example surveillance and monitoring solutions. This follows all the way through to visualization on a dashboard, including predictive maintenance and alarm messaging. UPDATE: What can the visitors expect next? Wilfried Grote: After this, we can delve deeper into subjects with those visitors who are interested, with the help of practical exhibits 285 m2 exhibition area
UPDATE 2|18 Trade fair preview 07 166,000 visitors from more than 100 countries Hall 11.1, Booth A27 3,859 exhibitors in total 46% of exhibitors from Germany (2015) such as large-scale models, real control cabinets, and action centers, as well as a classic key product presentation. UPDATE: So, the product is the main focus? Wilfried Grote: I would like to answer that with the classic "that also". Phoenix Contact is establishing itself here as a full-service provider for electrical, measurement, and control technology solutions (E-MCR), and as a solutions provider for the modernization and digitalization 30 employees at the Phoenix Contact main booth of process engineering systems. Our customers are showing an especially keen interest in the field of modernization, that is to say working with a stock of existing technologies. The demand is enormous here. Migration strategies for control or E-MCR technology, digital maintenance processes and paperless documentation, monitoring and the industrial use of web processes, as well as the complete range of communication solutions such as Foundation Fieldbus, HART, Profibus DP/PA, Profinet, Ethernet, and wireless networks are all a part of the umbrella subject of digitalization and modernization, and will be on display at our booth A27 in Hall 11. UPDATE: Thank you very much for talking to us.
08 Feature UPDATE 2|18 Trinseo produces the plastic polystyrene at its Tessenderlo facility in Belgium Change a winning team The example of a successful control system modernization project using a holistic concept To prevent long downtimes, the modernization of a control system should pass off as quickly as possible, and without any errors. A well-developed concept from Phoenix Contact ensures the reliable transfer of the field signals to the new control system. Trinseo, the chemical and plastics specialist, produces specialized polymer solutions at 19 facilities in 14 countries all over the world. The product range comprises a wide variety of thermoplastic resins. These include materials made from polycarbonate, technical polymers, ABS, polystyrene, and polypropylene. The control technology used previously in the production plants was commissioned in 1984. When it became apparent that it would soon no longer be possible to guarantee the supply of spare parts, Trinseo decided that it was time to modernize the control system. The challenge here was to integrate the existing single-strand wiring into a system solution. Wim van Drongelen, the Global Process Control Engineer responsible, developed a future-oriented concept together with the system cabling specialists from Phoenix Contact that had to satisfy four requirements: • Retention of the existing field wiring • Fast and error-free setup • Reduction in the number of I/O tests required • Minimization of setup costs Field signals are transmitted via Plug and Play In the existing system, the field signals were transmitted to the control system via terminal blocks with single wires. For the new control system, Trinseo decided upon the S800 from “ Retrofitting at all Trinseo facilities is to be completed by 2021.” Wim van Drongelen, Global Engineer at Trinseo ABB, the I/O cards of which are connected to the field signals via single wires. In order to be able to change over quickly and without errors, however, a Plug and Play solution with system cables between the field and I/O level was ideal. Trinseo uses VIP series termination boards in the new control system. Robust system cables
UPDATE 2|18 On site 09 provide the connection to the field level. At the heart of the setup are adapters for single and double-level terminal blocks both for left-hand and right-hand mounting. The color coding of the versions ensures easier assignment and faster testing in the system. The terminal blocks are therefore system-capable. Polystyrene is produced at the Tessenderlo facility. A critical component of the production system is a stirring tank reactor, in which the ingredients styrene and acrylonitrile are polymerized. The energy supplier already provides the necessary electricity via redundant grids, because an electricity outage occurring during the production process would destroy the stirring tank reactor and cause grave production downtimes. Therefore, a reliable control engineering system is essential for the smooth operation of the system. Preparation for a baptism of fire In order to mitigate the potential impact of this open heart surgery, the concept was first tested and optimized on a mini-plant system, that is to say a greatly reduced test system, in which the processes can be tested in a closed-loop framework. A one-year preparatory phase for setting up the facility then began. “We had to migrate 2,500 I/O signals,” explains Wim van Drongelen. “All of the signals had to be acquired and restructured. The I/O control cabinets, including the software, were then produced and supplied within just eight months.” The great clear-up The exciting part of the setup then began: commissioning. After setting up the control cabinets for the control system and removing the old single wires, the terminal adapters were mounted and the system cables were routed. Due to the structured system design, it was not necessary to perform 100% testing of the signals once a random-sample plausibility check had been performed. By using a mix of specific Phoenix Contact solutions and standard products from the Phoenix Contact system cabling range, Trinseo has realized a clear and structured control technology. Terminal adapters, pre-assembled system cables, and termination boards in combination with the pre-installed control cabinets guaranteed that the control system was able to be replaced quickly and without errors. The number of loop checks was reduced to 15 to 20 percent. This reduced the setup time by two weeks, and led to significantly lower costs. Due to the good experiences gained in Tessenderlo, further systems in Europe, Asia, and the USA have also been set up in accordance with this proven concept. Here, Phoenix Contact provided support with additional extended solutions that were necessary on a facility- specific basis, such as different length versions of the system cables. Trinseo is planning to complete the setup of all 35 systems with a total of 90,000 I/O signals by 2021. Control system cabinet: The plastics manufacturer uses VIP termination boards, pre-assembled system cables, and terminal adapters. Result: The setup was two weeks faster For further information, enter the web code #0702 into the search field on our website. Stefan Rücker Manager of the Solution Center in the Business Unit Interface Components
10 Technology UPDATE 2|18 Digital push for analog signals How can classic analog signals be integrated into a modern digital process controller? A robust analog approach in the field, but a digital process controller is waiting in the control center? With the MINI Analog Pro product range, Phoenix Contact has now created an easy and space-saving link. is very flexible. Troubleshooting in 4 … 20 mA measurement circuits is simple, and can be done without special equipment. Furthermore, almost every type of sensor is available with an integrated 4 … 20 mA transmitter. Nothing goes without the 4 … 20 mA measuring signal. For decades, sensors have been used in industrial systems to measure physical values, such as temperature, flow, and pressure, and to convert these into analog electrical signals. The signals are transmitted to a central control unit in the control cabinet and processed. Then, signals are issued from the control unit to actuators, such as electric motors, digital displays, and control valves. The established technology has weighty advantages: the 4 … 20 system world Omission is not a solution Large production systems often mean long cables. Due to external interference and disturbances, the signal only reaches the control unit in a deflected form – an exact representation of the measured signal cannot be reproduced on the input cards. This is where signal conditioners and measuring transducers come into play. The central control unit is made up of programmable logic controllers (PLC) or process control systems (PCS). However, in larger systems, users install what is known as an I/O level upstream of the actual control level. This collects the analog field signals and sends them bundled to the controller via a digital communication protocol – for example, Profinet or Modbus RTU/TCP. There are also signals such as temperature and frequency. Therefore, the structure described at the beginning often proves to be much more complex in reality, with more complex wiring, higher costs, and greater susceptibility to errors. And space in the control cabinet is tight. For the interface technology and an I/O level for, let's say, eight signals, roughly an additional 15 centimeters has to be planned on the DIN rail upstream of the controller. Fit for the app: Measured values can also be acquired via smartphone with a suitable app
UPDATE 2|18 Technology 11 In the center is the network adapter from the MINI Analog Pro product range with EtherNet/IP interface Therefore, interface modules are often omitted today. This space saving is relative, however, since signal-specifi c I/O cards are necessary as replacements. Furthermore, fl exibility is reduced if the design needs to be changed or repairs carried out. Another signifi cant disadvantage: the missing electrical isolation for each channel. The inputs of the module can thus be severely aff ected by external interference and infl uencing factors. Narrow on the rail With the MINI Analog Pro signal conditioners with bus and network connection, Phoenix Contact combines the advantages of analog measurement technology with digital communication. The front alignment of all terminal points and the patented FASTCON Pro pluggable connection technology simplify installation. The uninterruptible current “ Just as before, nothing goes without the 4 … 20 mA measuring signal.” measurement during ongoing operation supports service assignments on site. And despite large marking areas and status indicator LEDs, the signal conditioners are just 6.2 mm wide. All modules in the product range are designed for classic signal processing: an analog input signal is transmitted with electrical isolation to an analog output signal. In addition, limit values can be switched, digital input signals can be acquired, and measuring signals can be duplicated with a high degree of accuracy. The communication modules of the Mini Analog Pro series succeed in making the leap from analog to digital. They enable the direct connection of analog signal conditioners to serial transmission protocols. Systematic conversion The communication module digitalizes the output signals of the signal conditioners and measuring transducers. This enables the received measuring signals to be sent directly from the interface level to the control system or the controller. Thus, a previously unattainable modularity is possible, because in the pitch of 6.2 millimeters, any combination of standard signals can be realized. The I/O level can now be omitted. Signal conditioners and measuring transducers of the MINI Analog Pro series in combination with the corresponding communication module can replace expensive signal-specifi c I/O cards completely. The channel-wise isolation between the control and fi eld level ensures higher system availability. The modules can be commissioned and confi gured via a rotary coding switch, software, web server, app, or device description fi le. The current signals can be measured during operation in the event of maintenance actions without disconnecting the current loop. Using the NFC interface, confi gurations that were previously set in the MINI Analog Pro app are transferred from the smartphone to the signal conditioners. For further information, enter the Web code #2039 into the search fi eld on our website. Moritz Jung Product Manager in the Interface Analog department
12 Technology UPDATE 2|18 Hunter of hidden treasure Pimp up your data collection! The data has always been there, it just has to be used intelligently With smartphones, it has long since been the norm to install apps in order to gain better functionality. But does this also work for industrial systems, to extract more out of the available actuators and sensors? Diagnostic data is the key: monitoring the system status can improve the effectiveness of the entire system and be a part of predictive maintenance. Finding ways of performing calibration and configuration work remotely saves time, ensures increased efficiency, and improves safety for personnel. This must, however, be achieved without interrupting the ongoing system. Often, the additional data needed by the operator is already available. There are approximately 30 million HART devices installed worldwide. However, HART capabilities are only being used in around 10 percent of these. HART (Highway Addressable Remote Transducer) was standardized around 30 years ago, and is now the most broadly supported protocol standard in the process industry. HART was originally developed as a way of making analog process measurement devices “smarter” by superimposing digital data on a 4…20 mA signal loop. The standard continues to be developed with the introduction of new connection possibilities – including wireless connections and Ethernet. Eye of a needle interface But why is it that hardly anyone uses the data available from HART? The problem is, quite simply, the complexity. In many cases, process control systems or controllers that do not have HART capabilities were being used or specified. Thus, the control system was implemented A total of 30 million HART devices are installed worldwide, but the capabilities of this protocol are only used in around 10 percent of them INTERNET INTERNET Phoenix Contact PROFICLOUD Professional host service - SECURITY - AVAILABILITY Web browser DSC/analog out 4...20mA Mobile 3G/4G Ethernet HART: PV, SV, TV, QV Apps Third party applications 4...20mA HART “Data diode” t e n . y t i 24V 0V 24V 0V US ERR CON D S o r c M i Reset Micro SD LAN 1 LAN 2 ANT M S I R E T U O R C T . C B 3 1 D 9 . 5 4 . 0 A 0 0 . : . r d d A C A M 2 5 1 2 F C X A 7 6 2 4 0 4 2 . o N . d r O 8 7 6 5 4 3 2 1 : d r o w s s a p X3 UL a1 b1 a2 b2 PLCnext Technoligy Designed by PHOENIX CONTACT RUN FAIL DBG D E BF-C BF-D SF BOOT EXT p u t r a t s y s a e r o f e r e h n a c s SD-CARD R X4 n u m m o c - t x e n c p w w w . l S₁ H+₁ H-₁ S₁ S₁ H+₁ H-₁ S₁ PWR ST PWR ST S₂ H+₂ H-₂ S₂ S₂ H+₂ H-₂ S₂ S S U U B B - - I I / / N N U U H H T T E E L L P P W W G G S S U U B B - - 4 4 T T R R A A H H L L P P W W G G CH1 CH1 CH2 CH2 CH3 CH3 CH4 CH4 S₃ H+₃ H-₃ S₃ S₃ H+₃ H-₃ S₃ S₄ H+₄ H-₄ S₄ S₄ H+₄ H-₄ S₄ 3G/4G Router PLCnext controller HART gateway + 1...5 input modules (1...40 sensor connections)
UPDATE 2|18 Technology 13 With the modular gateway, HART data is integrated into the system via Ethernet without taking advantage of the additional measurement and diagnostic data that is available via a HART device. Industrial Internet of Things by walking: in this case, the HART interface was only used by maintenance personnel, who used a handheld device to perform local troubleshooting or calibration tasks in the system on the ground. If, in the past, system operators decided that they wanted to access the HART data, the users typically installed an RS-485 HART multiplexer, which had to be connected to a PC. Most PCs, however, did not have an RS-485 interface, meaning that an RS-232 converter was needed. Nowadays, most PCs no longer even have an RS-232 interface, meaning that users are forced “ Why does hardly anyone use the data from HART?” to purchase a device server for converting from RS-485 to Ethernet. This is a rather complicated solution with a number of devices that have to be configured and maintained. So the HART Foundation released a standard for HART IP, which is essentially a HART-over- Ethernet protocol. Therefore, a user-friendly interface for communication with the HART protocol is now available. And as a result, integration into tools that most plant operators and maintenance employees already use is possible. Treasure hunters from Blomberg A perfect fit: with the modular GW PL…-BUS HART IP gateway from Phoenix Contact, the data from HART devices can now be integrated and monitored via Ethernet. This enables easy integration into almost any host system, whereby the analog MCR loop remains fully operational. The gateway consists of a head station and a variety of HART extension modules to suit any application need. Up to five modules can be connected to the head station and communicate with up to 40 HART devices simultaneously. The modular design provides a scalable solution for modern distributed control systems and phased rollouts. The HART data is converted into HART IP, thus enabling communication with a large number of host applications. With SIMATIC PDM, the system also supports system maintenance via EDD (Electronic Device Description). Additionally, the GW PL…-BUS has been tested for compatibility and approved by Emerson for use with their AMS suite. Support for these applications provides the ability to operate intelligent system management via Ethernet. The device also integrates the standard industrial protocols Modbus/TCP and PROFINET, enabling users to establish connections with the control system of their choice so that they can take advantage of the additional process measurement data made available by HART devices. Therefore, users can now perform operations that save time and money, including loop checks, device calibration, partial stroke testing, and improved process monitoring with multivariable devices – all using the devices they already have installed. And so, the treasure is found … For further information, enter the web code #0636 into the search field on our website. Garrett Schmidt Wireless Product Manager, Phoenix Contact USA
14 Technology UPDATE 2|18 The cloud guarantees sunshine Monitoring of large-scale systems is greatly simplifi ed with Profi cloud. With signifi cant advantages for the operator We do it everywhere. The world of the cloud is all around us, whether when online banking, shopping, or looking for tomorrow's weather forecast. What if process data too could be retrieved completely independently of the location, and production processes could be infl uenced much faster as a result? The fi eld data is retrieved via a separate branch line for the Profi cloud connection, read off via the HART gateway, and suitably prepared. Up to fi ve HART devices, each with eight sensors, can be coupled to this front module. The data can be transmitted directly into the Profi cloud The world of the process industry tends to be largely conservative. This is no surprise, because interventions in the processes and controllers of refi neries or pharmaceutical and precision industries always carry risks. However, hard-nosed plant controllers of the old school cannot avoid the subject of digitalization in their older plants, because in a globalized world there are always innovations that quickly take a hold because they secure competitive advantages. Knowing what is going on in one's own production plant defi nitely plays a part in this. Phoenix Contact has developed a solution based on the NOA concept of the NAMUR automation pyramid that combines the monitoring of system statuses with the highest level of process reliability and maximum data protection: the Profi cloud. This solution solves the problem of access to process data being always available for analysts and service providers. Up into the cloud Above all, it is important to read process data off securely, and then to make it available to the operator in a secure system online. For the most part, these systems involve big data applications, for example rotating systems such as pumps, where predictive maintenance leads to real cost savings. It is important that the data can be read off and transmitted with the lowest possible amount of technical eff ort. via a PLCnext controller. As an alternative, the Profi cloud coupler establishes the connection between the local control system and the Profi net network through to the Profi cloud. Here, the Profi cloud device extends the Profi net network across the Internet. The connection is realized via a 3G/4G modem. With its onboard solution, the Profi cloud controller establishes a simple cloud connection in PC Worx Engineer. All distributed Profi cloud devices transmit data to the cloud via the Internet. This transmission runs just as smoothly as in the in-
UPDATE 2|18 Technology 15 house Profi net system. The datasets simply have to marked, then transmission to the Profi cloud is very simple. Also, thanks to TLS (Transport Layer Security) encryption, the data is reliably protected against third-party access. The security of a one-way streets The data, however, is not just encrypted. The entire Profi cloud system works faithfully in accordance with NOA principles in terms of the data diode, starting with the retrieval of the data via the HART gateway. Measured the availability, which must always be provided in a professional environment. Out of the cloud In the cloud, the Profi cloud Manager now works as a user interface, in order that access can be managed and data viewed. And in order that the appropriate data “pours” back out of the cloud, whether to the controller or, for example, for predictive maintenance, access via a completely normal web browser is suffi cient for calling off and evaluating the data. With its product range, Phoenix Contact is therefore not just a hardware provider, but, “ The data is reliably protected against third-party access.” data can only be retrieved in one direction. It is not possible to infl uence the systems back through the Profi cloud, thus ruling out external access to the system. The data is stored on the Amazon Data Warehouse servers. This company has set up its servers Germany, and is therefore also subject to the strict German data protection laws. The security of the data fl owing in there is therefore subject to the same extremely high demands as with the Profi cloud solution, it also provides a software environment that is tailored to the operators of processing plants. For further information, enter the web code #2031 into the search fi eld on our website. Thilo Glas Market Management Process
16 Technology UPDATE 2|18 Not without my tablet! Is the processing plant really “ready for Maintenance 4.0”? It must be if Maintenance 4.0 is to succeed It is always there. These days, most of us can hardly imagine locating an address in a foreign city or even one in our home town without using the digital navigation features of our own smartphones. Technology that has long been the norm in our personal lives would also be desirable for many workers who maintain and operate large systems in the chemical industry: a handheld device that guides them through the complex facility precisely to the device or the machine that the employee is to inspect. In fact, even the “road signs” are often missing. The old plastic signs in brownfield plants may be weathered, metal signs filthy or corroded. For employees who know their system like the back of their hand, this is not a problem; they will always find their way to the destination. further. These tags remain readable for a long time, even if a layer of dust forms on them over the years. Analog, but indispensable RFID HF is the short-range approach that relies on contact with the reader. RFID UHF, on the other hand, can “broadcast” over several meters. Thus, for example, transmitters mounted on a pipe bridge can be detected from below without scaffolding. A distinction is also made between active and passive RFID tags, which must be taken into account especially when they are used in potentially explosive areas. The tags can be incorporated into plastic labels, cable ties, or foil stickers. Furthermore, some field device and electronics manufacturers integrate them directly into their devices. But new employees or third-party contractors When printing, the same framework tasked with performing maintenance and repairs will have difficulties. This wastes time and, in the worst-case scenario, can lead to mistakes. Efficient maintenance, however, demands safe and easy orientation. The most obvious solution is still analog: durable signs, such as laser-engraved stainless steel markings. Using RFID markings takes this idea one step conditions are to be observed as with signs without RFID. In addition to the standardized key, you can also use bar or QR codes that are registered via camera apps. With a tablet and the appropriate software, the maintenance technician is guided to all components to be inspected much more efficiently than with any type of paper-based routing slip. Comprehensive WLAN: Maintenance software on an industrial handheld device guides employees and enables them to access documentation on site quickly and without errors Configuration WLAN network “Production 1” Industrial Ethernet
UPDATE 2|18 Feature 17 Companies that have fulfi lled the prerequisites for Maintenance 4.0 with clear markings and a reliable wireless network can move on to the next phase and test the fi rst mixed-reality applications for maintenance processes If fully rolled out, routes can be optimized automatically using this approach, and documentation of the inspection tour is simplifi ed. The employee identifi es himself on site with the handheld device and can confi rm the maintenance procedures online as soon as they have been performed. WLAN in every nook and cranny An essential prerequisite for this is a comprehensive WLAN network in the fi eld. In the same way as for markings and RFID tags, the wireless network must be well planned. Depending on whether the IT department or the production or maintenance team is responsible for installing and operating the network, there are two diff erent solutions available on the market. Powerful offi ce networks are often based on a server system with client hotspots. These can only be managed by experts. If such a concept is to be extended to production facilities, the IT department must be responsible for it. If the wireless network is to be installed and managed independently and fl exibly by the personnel of the control/MCR technology team, it should be ensured that the access points (as with the web-based cluster management system from Phoenix Contact) can still be managed centrally. Thus, for example, network and security settings can be transmitted easily to all devices simultaneously. This is an enormous advantage, because it is often the case that the providers' components need to be confi gured and maintained individually. On the hunt with glasses There is now just one step to go to reach Maintenance 4.0: augmented reality (AR) applications. The tablet, which has identifi ed a system part via camera or RFID for example, then displays further information on the camera screen: measured values, data sheets, maintenance instructions, or a video showing the work steps to be performed. Phoenix Contact is gathering practical experience itself: in its in-house production center, the temperatures in plastic injection mold machines or the statuses of pumps and motors are displayed with AR. The employee can use gestures to open a maintenance sheet or an exploded diagram, and bring them into view in 3D. Not so long ago this was a product purely for the gaming scene, but now AR is reality in the professional industrial environment. For further information, enter the web code #2038 into the search fi eld on our website. Wilfried Grote Director Industry Management Chemical and Pharmaceutical Industry
18 Technology UPDATE 2|18 Consistently isolated, responsible together A new dimension of safety is reached with the new generation of redundancy modules True story: the gas torch above the refinery in Gelsenkirchen burned for several days, resulting in several inquiries from local residents and the press. This disruption to operations caused tens of millions of euros worth of damage. It was caused by a short circuit in a substation. Redundant power supply concepts are used wherever a failure in the supply voltage would either result in enormous costs or could have an impact on people and the environment. In these scenarios, a redundant supply of power is already ensured by the parallel operation of two power supplies that are connected by a redundancy module. Single- channel S-Oring modules combined with the new Quint Power power supplies from Phoenix Contact drastically increase availability – which was already high. Redundant power supply systems are typically used in the oil and gas sectors, as well Consistent isolation of the current paths up to the load increase the already high level of protection as in the chemical industry. In other industries such as glass manufacturing, however, the failure of the auxiliary power supply can quickly lead to the loss of an entire batch. Other areas of use include power stations. With redundant supply concepts, two power supplies are operated in parallel, such that the second power supply can completely take on the load if the first one fails. To ensure “ Here, the failure of a controller can lead to very high costs or serious incidents.” this, the power supplies must be rated such that just one module can cover the full power requirements of the connected loads in all operating states. For the highest demands The new Quint S-Oring modules have been developed for users with extremely demanding requirements in terms of supply voltage availability. The Quint S-Oring redundancy module was developed together with process automation customers who wanted to increase the already extremely high availability provided by the existing Oring modules to the maximum extent possible. By consistently isolating the current paths, and therefore isolating the various potentials up to the load, the connected loads continue to be supplied reliably even in the event of one of the redundancy modules failing. Even servicing and maintenance work will not disrupt the continuous power supply.
20 Technology UPDATE 2|18 Examining who connects and how No Industrie 4.0 without functioning data transmission In the age of digital field device networking and high-speed data streams to control centers, even micro-interruptions between measuring devices and data lines are the enemy of smooth system control. Profinet, the innovative and open standard for Industrial Ethernet, has become established for data communication in the industrial environment. Profinet, the acronym for Process Field Network, can be used wherever intelligent, real-time production and process automation systems are to be realized. Along with applications in the automotive industry and machine building, Profinet is also used as the communication standard for control computers, controllers, and smart field devices even in the harsh environments of the chemical industry, in the environmental and recycling fields, metal production, and the areas of water and wastewater technology. Because the demands on general Ethernet-based communication networks differ greatly, Profinet was developed for the demands of production environments. To ensure that information is consistent, real-time behavior is facilitated, and system devices are adapted to the environmental conditions, the Profibus User Organization (PNO) describes techniques and requirements of compatible components and devices in its “Guideline for Profinet”. The “constrained” world of Industrial Ethernet As copper-based Profinet interfaces, established RJ45 connectors and M12 circular connectors were previously approved for Ethernet applications. However, RJ45 is meeting its limits here, because it originates from the office sector. This is often not the ideal choice for harsh vibration environments such as those found in the process industry, because the relatively sensitive connector was simply not designed for this. Its connection weaknesses, which are exacerbated in these environments, can lead to failures and errors in the process. When used in harsh environments, the signal must not become faulty due to external interference
UPDATE 2|18 Technology 21 A flow measurement sensor with Profinet connection via a PCB terminal block The fourth version of the Guideline, issued in May 2017, states that PCB terminal blocks can also be used as Profinet interfaces in field devices. The advantage of this in comparison with RJ45 or M12 connections is, on the one hand, a higher level of mechanical reliability, due to the contact being directly on the PCB. Using a PCB terminal block makes a male-female connection superfluous. On the other hand, the terminal blocks are significantly easier to connect. Plug assembly is dispensed with – meaning that the installers can connect the field devices more easily and efficiently. Because PCB terminal blocks are normally designed with protection class IP20, they belong inside the field devices (see figure). They are equipped with Profinet-compatible shielding and conductor strain relief. The requirements that the terminal must meet include the marking of the contact point for the clear assignment of the single Profinet cable conductors, whose compatibility also has to be “ PCB terminal blocks can now also be used as Profinet interfaces in field devices.” ensured. The high-speed data transmission of category 5 in accordance with IEC 11801 is also a requirement, as is the capability for Power over Ethernet power transmission in accordance with IEEE 802.3at. The often harsh conditions in the industrial field also demand that the requirements of the area of application are complied with too. The Guideline therefore takes into consideration the requirements in terms of shock and vibration resistance in accordance with IEC 60512, among others. the type of protection Ex e in accordance with IEC 60079-7 for potentially explosive areas. At the end of 2017, Phoenix Contact became the first manufacturer to launch a range of PCB terminal blocks qualified for Profinet which, for the most part, also have an Ex approval for potentially explosive areas. Various product ranges for Profinet connection are available to satisfy the individual device design requirements of customers. These include terminals with Push- in spring, screw, and spring-cage connection. Depending on type, these are equipped with the conductor connection directions horizontal, vertical, or offset by 45° to the printed-circuit board. In the first phase, only terminals for use with quad-core Profinet cables are available. With these, data is sent via one conductor pair and received via another. To eliminate electromagnetic interference, the wire pairs are twisted outside of the cable shield braiding. The Phoenix Contact PCB terminal blocks qualified for Profinet have everything that a device interface needs in a harsh process environment. They extend the range of existing M12 and RJ45 field and device connectors, and provide efficient connection solutions for all devices in the process industry. For further information, enter the web code #1598 into the search field on our website. Protection against explosions Along with the relatively general requirements for Profinet, the respective application-specific requirements must also be complied with. It is often required, for example, that compliance be assured with increased safety requirements of Thomas Neuendorf Product Manager for PCB Terminal Blocks
UPDATE 2|18 Technology 25 prior to a fl u epidemic, for example, the operator can simply number up by ordering further containers, instead of performing a time-consuming and costly scale-up – i.e., constructing a larger plant. This procedure requires signifi cantly less time and money, because the already established process does not need to be changed, rather it only needs to be duplicated. Controllers are necessary It is not, however, suffi cient just to break a processing plant down into modular units and to continue to control these centrally. Rather, a concept is required that allows the modular and thus locally controlled units to be integrated into the central process control system. At the NAMUR AGM in 2016, automation manufacturers described a previously defi ned container processing plant. By converting the various data streams into a standardized XML format, it is possible to integrate the various control systems into the process control system. The individual modules appear identical to the end user, while the process engineer is responsible for the processes in the background. All modules perform in accordance with a jointly adopted standard. The advantages are clear: shorter development times, faster product maturity. The option of reusing the separate modules saves time and money. The product volume is easily scalable. And the modules can be more easily provided, maintained, and, where necessary, adapted by the suppliers. The same software concepts in process and production technology Overall, modular automation provides new possibilities in the chemical industry for satisfying ever more individual customer demands at a reasonable cost. Industrie 4.0 is thus being realized simultaneously in both process and production technology. The specifi c requirements of process technology are resolved with the same software concepts that are used in factory automation. Thanks to the high fl exibility of the production process together with the high quality of the manufactured products, the population can stop worrying about the next fl u epidemic. Claus Vothknecht System Manager Process Industry Central control system Centralized automated system part Modular systems require a sophisticated central process controller that can integrate the movable production units into a fi xed system Decentralized automated system part Decentralized automated system part Decentralized automated system part
26 News UPDATE 2|18 “ We made it clear at the Hannover Messe 2018 that we are with our partners and customers on the path to digitalization and Industrie 4.0 every step of the way.” “ Thanks to the data consistency displayed in the workshop area of the booth, Industrie 4.0 came alive. This impressed our visitors, our customers, and me.” “ We develop large-scale charging infrastructures. With our partner Phoenix Contact, we can provide our customers with individual solutions tailored to their needs.” Roland Bent, General Manager Phoenix Contact Sophia Bulmahn, Project Manager Digitalization Phoenix Contact Dr. Fabian Sösemann Head of Energy Supply GP Joule 5,800 trade fair exhibitors in total 230 exhibits 450 employees working in the booths 2,800 m2 exhibition area 1,200 delegates from more than 50 countries Hannover Messe 2018 A trade fair of superlatives – the Hannover Messe was a home game and a challenge at the same time Phoenix Contact was the third largest exhibitor at the world's leading industrial trade fair. Phoenix Contact was omnipresent, with a spectacular main booth and eleven further booths spread throughout the grounds of the Hannover Messe. And with the main theme being “Integrated Industry – Connect and Collaborate”, the focus of this year's Hannover Messe was practically tailor-made for us. The exhibits ranged from classic terminal blocks through to digital data glasses. Whether PLCnext or charging station technology, whether cloud connection or building management – the interest from both domestic and international visitors was immense, as was the congestion! The fi gures above underline the signifi cance of the Hannover Messe and the success that Phoenix Contact has achieved this year.