Virtual commissioning of drive solutions.

NORD now offers digital twins for system development. Based on a myNORD configuration, it is now possible to request individually created drive systems as simulation models. This allows engineers to verify early in the planning phase whether the drive concept is suitable for the system. Virtual commissioning significantly reduces the project time even for complex systems.

Since the publication of the FMI (functional mock-up interface) technical standard in 2010, it has become more and more common to work with simulation models in system planning. NORD Drivesystems also uses data-based simulations for the development of its components and drive solutions. The system provider is now using this know-how to help its customers achieve greater efficiency and availability of its drive systems even in the planning phase by offering a digital service: With digital twins of its drives, NORD enables virtual commissioning.

Users can configure drive systems or components for their requirements as usual via the myNORD customer portal. They select components and their features such as performance, mounting options or outputs. Then, they can request a simulation model for the fully configured drive system. The process was developed by NORD in cooperation with the software company Machineering from Munich, which specialises in virtual commissioning.

The advantage of these digital twins of the NORD solutions is the significantly faster availability of the entire system. The simulation models are inserted into a similarly simulated system. In this environment, the drive configurations can be extensively tested. If adjustments are required, they can be easily implemented based on the data. Errors can be remedied in the early stages of development, avoiding potential later damage. Only once the virtual drive system has been validated by the customer, it will be manufactured and delivered by NORD. As the drives are already functionally integrated into the system control at this point, actual commissioning is possible in a very short time. The overall process from configuration to commissioning is reduced from several months to only a few weeks.

Virtual commissioning of drive systems is of special interest for any technically demanding solution. Therefore, NORD particularly focuses on components that play a decisive role in automating production processes. The manufacturer is kicking off the virtual commissioning with its range of high-efficiency IE5+ and IE4 motors, along with the corresponding gear units and frequency inverters. Simulation models will then gradually become available for other NORD product areas as well.

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@NORD_Drive @mepaxIntPR #Pauto

Pneumatic Valve System with Embedded Wireless Connectivity.

Emerson has introduced a wireless automatic recovery module (ARM) for its AVENTICS™ G3 electronic fieldbus platform that makes it easy for technicians to perform pneumatic valve system commissioning and diagnostics from a mobile phone, tablet or laptop computer.

“The AVENTICS G3 fieldbus platform is the first in the industry to offer wireless technology that puts valve system configuration and diagnostics at the control engineer’s fingertips,” said Enrico De Carolis, vice president of global technology, fluid control and pneumatics, at Emerson. “This offering furthers our quest to help manufacturers reduce production downtime and simplify valve system commissioning, while creating a path for using diagnostics/prognostics for analytics and advancing our offering of intelligent devices with IIoT capability.”

The new wireless ARM module and AVENTICS G3 fieldbus platform are ideal for pneumatic valve system applications in the automotive, food and beverage, tire, packaging and metalworking industries.

The wireless ARM module provides easy access to the AVENTICS G3 fieldbus platform’s diagnostic and commissioning capabilities via an internal Wi-Fi access point and mobile website — even when the valve system is located inside a machine or on a ceiling. It offers the visual benefits of a hard-wired human machine interface (HMI) at lower cost and with higher flexibility. The wireless ARM module generates error notification for alarms, voltage levels, short circuits, module errors, open load errors and distribution errors to reduce system downtime.

The device has a small footprint that connects easily to the AVENTICS G3 fieldbus platform in the space of a jumper clip. It features three power settings for low-, medium-, or high-distance signals to ensure safe and secure access to data — regardless of where the valve system is mounted. Additional security benefits include wireless signal that can be turned off during configuration, multiple password options, and diagnostic and commissioning information provided with no control capability.

The wireless ARM module is compatible with Ethernet/IP DLR, and PROFINET protocols. Additional protocols are targeted for future release.

The  module also protects the AVENTICS G3 fieldbus platform’s configuration information from a critical failure, including all settable node and attached I/O module parameters.

Emerson also has introduced an upgraded ARM clip for the AVENTICS G3 fieldbus platform that is backwardly compatible to existing ARMs and G3 fieldbus platforms. The ARM clip improves system reliability by protecting configuration information from critical valve system failure.

The AVENTICS G3 fieldbus platform’s electronic parameters and settings are automatically stored in the ARM’s nonvolatile memory and then the ARM is automatically disconnected from power, to ensure stored information is not erased during a power spike or critical failure. “A replacement G3 fieldbus communication node can automatically download the required parameters from the ARM module,” said De Carolis. “This enables the valve system and production line to quickly resume operation without the need for re-commissioning by a controls engineer, offering true ‘plug and play’ capability.”

The compact ARM module is easy to install in the space of an AVENTICS G3 fieldbus platform’s jumper clip without having to change the mounting.

@Emerson_News @EMR_Automation @AVENTICS  #PAuto #MEpax 

Digital service expanded.

Digital commissioning application and Netilion turnover package provides added value services to ensure projects stay on time, on-budget, and up to date on project steps.

Project benefits include:

• Real time visibility and insights of work progress, issues and completion
• Efficient project setup, automatic data sheet, tag lists and template uploads for improved work planning
• Collaborative, dynamic digital guide for work process execution
• Intuitive, easy app for all techs and supervisors to learn, use and enjoy
• Evergreen digital turnover package powered by Netilion IIoT connected services.

Endress+Hauser's end users’ digital experience on instrument projects has been expanded with the release of their digital commissioning application and Netilion projects digital turnover package. These new capabilities empower the plant startup team to mitigate project risks while staying on time and budget, and to track progress in real time.

The digital service experience enables users to digitize projects for efficiency, eliminating time consuming manual coding and progress reports. Users are able to see project work progress across the field devices startup phases in real-time and can flag any potential issues on the commissioning app. Visibility to issues enables users to reallocate resources to keep the project on time. The web-based application workflow is tailor built to field technician and project manager user’s needs for greater productivity.

Instead of manual loop folders, documentation is generated digitally and stored in the Netilion Library digital service application. This paperless storage eliminates manual retrieval to facilitate development of a turnover package complying with project deliverable requirements.

Netilion Library helps users organize asset records, drawings, pictures, files, and turnover package documents. It is a file sharing and data management service for the complete life cycle of an instrument. This saves significant time when carrying out maintenance or engineering activities since the often-tedious search for information is eliminated.

@Endress_Hauser @Endress_US @Endress_UK #PAuto 

5G for industry in Europe.

With its campus networks, Deutsche Telekom offers an infrastructure for the smart factory of tomorrow. Together with partners from industry, Europe’s largest telecommunications company wants to further expand its 5G ecosystem for industry. In process automation, Deutsche Telekom is now cooperating with Endress+Hauser.

The aim of the cooperation is to develop joint offers in the field of measurement and automation technology for the process industry. This involves the integration of measuring instruments and accessories into the next generation of mobile communication networks as well as digital services based on them. Both companies have signed a corresponding memorandum of understanding and are now working on a coordinated timetable.

Endress+Hauser is one of the first manufacturers to equip its field devices with mobile communication modules and to connect existing installations to 5G networks via newly developed HART gateways. This enables a large number of instruments to transmit a wealth of process and device data in parallel and in real time. These can, for example, be used in cloud applications for predictive maintenance of process plants.

Matthias Altendorf

“In addition to the actual measured values, our instruments record a wealth of information from the process and about the sensor,” says Matthias Altendorf, CEO of Endress+Hauser (pictured right). “5G campus networks open up a second signal path that is independent of the plant’s control system and thus make it possible to tap this potential. This will enable us to link value chains more closely across company boundaries and make industrial processes more efficient.”

“Building a complete 5G ecosystem for industry will accelerate the pace of digitalization in industry,” explains Claudia Nemat, member of the Deutsche Telekom Board of Management, Technology and Innovation. “We look forward to working with renowned and experienced partners.” 

In addition to the partnership with network supplier Ericsson, the telecommunications company now also cooperates with E&K Automation, a manufacturer of driverless transport systems, and Konica Minolta, which offers augmented reality glasses, among other products.

#PAuto @Endress_Hauser @Endress_UK @Telekom_group

Tablet PC for hazardous areas.

The introduction of the Field Xpert SMT77, a rugged tablet PC tool for commissioning and maintenance staff to manage field instruments and document the work progress expands Endress+Hauser's product portfolio for device configuration. The SMT77 comes preinstalled with device configuration software and device library —so it is ready to go, right out of the box. The device enables plant asset management in Class 1 Div 1 hazardous areas.

Like the Field Xpert SMT70 (Class 1 Div 2 rated), the Field Xpert SMT77 supports HART, PROFIBUS DP/PA, Foundation Fieldbus, Modbus, CDI and Endress+Hauser service interfaces.

The Field Xpert device library has more than 2,700 pre-installed device and communication drivers, allowing it to work with many different instruments from a wide variety of vendors. It can connect to field instrumentation devices directly via a USB or Bluetooth wireless modem, or via a gateway, remote I/O or multiplexer to a bus system.

The Field Xpert SMT77, therefore, works with virtually every modern field instrument with “One Click Connectivity.“ To connect the Field Xpert SMT77 to a flowmeter with HART interface, for example, the operator simply clicks on the application, which then prompts the user to select automatic connection and the application connects to the instrument, and the SMT77 is ready to perform diagnostics, configurations or commissioning with the built-in device configuration software. The SMT77 also supports Endress+Hauser Heartbeat Technology and FieldCare instrument diagnostic and monitoring functions.

The tablet PC has Windows 10 Pro software installed. It comes with an 10.1 inch LCD Multitouch HD display, 2x bonded Gorilla Glass, a 5MP auto focus camera, a 2MP front facing camera, and up to 128 GB storage. Communication ports and supported networks include USB, Ethernet, HDMI, Wi-Fi and Bluetooth—with 4G LTE and GPS available as an option. The battery runtime is five hours. The SMT77 comes in a general purpose configuration as well hazardous area configuration for Class 1, Div 1 and meets all the legal requirements of the relevant EU directives and is IP65 compliant.

 #PAuto @Endress_Hauser @Endress_US @Endress_UK

Diagnostics and commissioning networks.

Softing has introduced an enhanced version of the proven PROFINET commissioning and diagnostics tool Analyzer IE. The new version is called Analyzer PRO and allows the measurement of passive parameters that give a more detailed insight into the PROFINET network.

As an enhanced version of the commissioning and diagnostics tool Analyzer IE, Analyzer PRO includes a TAP (Terminal Access Point) device called “profiTap”. profiTap records network communication such as jitter, load ratio and device update rate. These so-called passive parameters cannot be determined via actively communicating to devices. With the help of profiTap, all packets traveling to and from the controller are analyzed and network communication is recorded. Eventually, the parameters are integrated in the acceptance report and add an additional layer of information which provides more detailed insights into the PROFINET network.

Analyzer PRO is the combination of Softing’s products TH SCOPE software and TH LINK PC. It monitors and diagnoses the health of industrial networks so that field devices continue to communicate with PLCs which would otherwise cause plant downtime or outages. The generated acceptance reports correspond to the recommendations of the "PROFINET Commissioning Guideline" from PROFIBUS & PROFINET International (PI). Analyzer PRO is tailored to the needs of maintenance and production operations and requires no IT or network expertise on the part of the user. In addition to the PROFINET standard, EtherNet/IP, Modbus TCP and PROFIBUS are also supported.

 @SoftingIA #PAuto

Faster and Safet start-ups!

Maverick Technologies, (now part of Rockwell Automation), has announced the release of eStart℠, a groundbreaking new app that keeps projects on track by making commissioning more efficient and transparent than ever. When outage windows become condensed, even the slightest inaccuracies in project tracking can have a major impact. Maverick is responding to these challenges with eStart.

At the beginning of a startup and commissioning project, they use eStart to digitally gather data and create loop folders to house all relevant instrument data and checksheets. Digital folder creation not only greatly reduces documentation time, but also keeps all electronic data at the technicians’ fingertips, anywhere they are. In addition, eStart’s Near Me feature uses GPS technology to locate nearby instruments and identify which stage of commissioning they are in, to make loop shooting more efficient.

“Loop shooting and documentation can eat up a lot of time,” says Consultant Mark McMakin. “With eStart, loop-shooting time is reduced by up to 10% and documentation time is reduced by up to 30%, ensuring a more efficient workflow.”

eStart also offers customers greater visibility into their commissioning projects. Every time a step is completed, the app automatically records the technician’s name, date and time stamp, giving customers real-time updates so they always know how close the project is to completion. This way, if the schedule slips, customers can proactively make adjustments to get back on track.

The breakthrough eStart app is a fully integrated feature of the company's proven SureStart solution for startup and commissioning. With SureStart, their construction managers, technicians and electricians work in parallel with construction efforts to minimize downtime, enhance reliability and finish ahead of schedule. The result is faster and safer startups.

@MavTechGlobal #Pauto @ROKAutomation 

Commissioning made easy!

Emerson Process Management has introduced Smart Commissioning, a technology-enabled process that drastically reduces automation commissioning time and effort. Smart Commissioning helps automation projects meet strict and shifting deadlines by reducing trips to the field, eliminating tasks, and accommodating late project changes. Smart Automation Commissioning builds on advances made possible by the combination of the DeltaV™ distributed control system (DCS), Electronic Marshalling with CHARMs and AMS Device Manager software to remove automation from the critical path of projects.

With the release of version 13 software for the DeltaV DCS and AMS Suite, Smart Commissioning brings ease to automation project implementation. From the initial device connections to final system testing, users save money as they shave weeks off the project schedule by reducing time spent on automation commissioning activities.

Upon arrival at a project site, pre-tagged smart devices can be connected immediately to any channel in a nearby junction box - no need to wait for wiring designs to be complete. Smart Commissioning also eliminates potential errors by automatically finding and identifying all smart devices, then binding them to the configuration. To further accelerate implementation, the device configuration is pushed to all devices based on pre-configured templates. Testing is easily and safely done from the control room by using digital communication, requiring no personnel in the field for confirmation.

“With Smart Commissioning, members of the project team can more easily meet tight project timelines and are not hampered by late design changes,” said Mark Howard, vice president of project execution for Emerson Process Management. “Developed based on industry experience, this solution is another step from Emerson toward attaining project certainty for users.”

CNC programming software for operations planning, training and sales.

In Sinutrain version 4.7,  Siemens has simplified its Windows PC-based offline programming software for machine tools, and equipped it with new, practical functions. For example, in the new workbench interface, the previous selection list has been replaced by a clear home page with animated images. This enables the user to quickly obtain an overview as if present in a virtual machine hall.

Background information:
Sinutrain is a Windows PC-based CNC programming station for machine tool controllers, which has an identical controller and uses the same programming and user interface as Siemens Sinumerik controllers. Sinutrain is used for operations planning, training and sales. Manufacturing companies use the software in their operations planning to program and simulate the next order offline in advance on a computer – without blocking expensive machine tools CNC programming is practiced in training in exactly the same way as on real machines. The field sales workers of machine and controller manufacturers just need laptops to demonstrate machine tool processes. Sinutrain has the same Sinumerik Operate user interface as Sinumerik machine tool controllers, so employees can work in the same engineering environment both offline and directly on the machine.

Clicks are made on the desired machine to select it and is immediately taken to the correct programming interface for his NC program: to the workshop-oriented ShopMill/ShopTurn machining step programming, the cycle-supporting programGuide G code language, or the DIN and ISO commands.

The DXF (Drawing Interchange File Format) reader newly integrated in Sinutrain 4.7 simplifies both the exchange of data with CAD systems and the program creation. The CAD data is read in with a few clicks and part programs are created much more quickly. The possibilities of creating new machine tools have also been improved. As an option, the IBN (commissioning) archive can now be read in from machine tools. This makes all the data stored in the CNC also available in Sinutrain. For example, manufacturers' cycles, including cycle images from machine manufacturers, can be copied from the real machine to Sinutrain.

The standard machining process templates have also been expanded in Sinutrain 4.7. These enable users to create executable programs quickly, e.g. for turning and milling machines. These include not only turning with or without a counterspindle, and 3 to 5-axis milling, but also combined milling-turning. This enables functional programs to be created easily for machine tools – irrespective of their size, power and manufacturer.

Another special feature available for the first time is the free basic version of Sinutrain 4.7 without any runtime restrictions. Sinutrain Basic can be obtained online here, and is especially useful for sales and basic training. For example, programs from demonstration machines for 3-axis milling machines or 2-axis turning machines can be transferred to and executed on appropriate machining centers in the same way as with the full version. There are also special training packages for training institutions, with additional student licenses and programming manuals.

From the Very First Click.

The new FieldConnex fieldbus diagnostic handheld device (FDH-1) from Pepperl+Fuchs makes commissioning and troubleshooting a fieldbus installation easier than ever. The mobile device can check any fieldbus segment quickly and easily with the simple press of a button.

"Easier than using a multimeter!"

To make it even easier to install and use the fieldbus infrastructure, Pepperl+Fuchs has developed the new FieldConnex fieldbus diagnostic handheld device (FDH-1). Is the desired signal quality achieved? Is the bus termination correct? The FDH-1 uses a quick and simple method to display the quality of the fieldbus installation. The handheld has been specifically designed to be easy to operate without the need for expert fieldbus knowledge. Just connect the handheld to any fieldbus segment; no PC required! This connection enables the handheld to show whether or not there are any errors in the physical layer installation prior to commissioning a segment. If there are errors, it will pinpoint what they are, where they are, and how they can be corrected. This saves time and money during installation. The FDH-1 can also be used to check existing cables in to determine whether they are suitable for a fieldbus installation. Taking this approach can lead to considerable savings in terms of cabling costs and the amount of maintenance work required, ensuing reliable operation of the fieldbus. In existing installations, the FDH-1 can check the short-circuit protection at the spur connections. This is especially advisable for fieldbus installations that are many years old and may be beginning to experience problems.

The Mobile Expert
The new FDH-1 handheld device makes the commissioning process easy and ensures that quality assurance of the fieldbus installation is extremely straightforward. The mobile device is incredibly simple to handle and requires no previous technical knowledge, providing a crucial advantage. The device is just as user-friendly as the trusted multimeter, but can do a great deal more. For example, it features an integrated expert system that interprets the measured values, enabling it to detect errors and determine exactly where they are located. Once the errors are detected, it will also provide a simple corrective action statement. In addition to this expert system, a commissioning wizard with guided dialogs ensures the handheld device is easy to use. The wizard compares the installation to values set from fieldbus standards and specifications, enabling a target/actual comparison. If required, the wizard can create documentation in a storage format that can be downloaded via USB. The test report can also simply be downloaded again at a later date and used for comparison measurements.

The new FieldConnex fieldbus diagnostic handheld device from Pepperl+Fuchs makes the fieldbus installation as easy and straightforward as possible, providing the ideal basis for trouble-free operation and maximum availability of processing equipment. The FDH-1 is approved for use in all hazardous areas and for all types of explosion protection.

Harmonization of C& Q and CSV initiatives!

Forthcoming Technical Talk from the ISA Ireland Section is to be held at Rochestown Park Hotel in Cork on Wednesday, 18 February 2015 @ 19.00hrs sharp.

The Speaker

Jorge L. Rodriguez is the Founder, President and CEO of PACIV, a control system engineering firm. PACIV has offices in Puerto Rico, United States and Ireland. PACIV provides operational efficiencies through the automation of manufacturing processes utilizing instrumentation and control systems. PACIV clients include the largest Biotechnology, Pharmaceutical, and Medical Device companies in the world as well as other multinational clients in related industries. PACIV has over 120 associates world-wide and has revenues, in the past 16 years, of over $135 million.

Prior to founding PACIV, he worked for over 8 years as a control system engineer in various positions within Westinghouse Electric, Eli Lilly & Co. and J&J Janssen.

“Harmonization of C&Q and CSV Initiatives” by Jorge L. Rodríguez – President & CEO – PACIV

In many instances there is significant overlap between the computerized system validation and the commissioning and qualification activities specially for computerized control systems utilized in the manufacturing, facilities and/or utility processes (e.g. PLC’s, SCADA, DCS). As such, these efforts may be combined under one effort, to ensure proper synchronization and preclude duplication of effort. As a result, a single validation/qualification effort may be performed to produce the required deliverables to achieve compliance while harmonizing work being done even when using different teams. Moreover, the commissioning effort can reduce significantly not only the qualification effort but also the CSV effort, if performed appropriately.

In today’s competitive environment, clear and concise policies and procedures that promote such harmonization effort, regardless of the type of regulated manufacturing process and automation platform, will offer significant value by reducing the cost as well as the time it will take to complete such projects while still meeting the required level of compliance.

• Pre-registration on the ISA Ireland website would be helpful (not necessary to attend) as it would give us an indication of how many to expect on the night. On the section website under “Upcoming Events” for Wednesday 18 February click on “more info”, then follow the next prompt and click on “info” for ISA Tech Talk and you will notice a registration template at the bottom of the page.