Plug and play in industrial plants

Contradictory to the common belief that technology necessary for Industry 4.0 is expensive, the Combine and Conquer report by Accenture found that combining technologies such as AR/VR, big data and machine learning can save large businesses an average of £60,000 per employee. 

Here, Nick Boughton, sales manager at industrial systems integrator, Boulting Technology, explores the growing trend of plug and play technologies. 

Despite Industry 4.0 being far from a new concept, first being coined in 2011 at the Hanover Fair, the long lifespan of industrial machinery and the high perceived costs associated with purchasing smart technologies means manufacturers may still be reluctant to take advantage of the Industrial Internet of Things (IIoT).

A growing trend for many manufacturers looking to ‘smarten’ up their factory and integrate Industry 4.0 technology’s such as remote monitoring and predictive maintenance, is the introduction of plug and play devices. However, with growing concern about vendor lock-in, choosing hardware that is compatible with the existing products within a plant is essential to saving costs in addition to ensuring compatibility. 

Plug and play
Plug and play devices are one way of maximising compatibility between new products and existing systems.

A plug and play device or computer bus has a specification that allows for the discovery of a hardware component in a system without physical device configuration or user intervention.

A multitude of IoT functions are now available with plug and play IoT kits. One popular example is the use of sensors that allow for digital condition monitoring for any kind of machinery. A direct physical attachment means they are able to take measurements such as vibration and temperature to facilitate maintenance plans, without any compatibility complications. 

Because many manufacturers and developers of industrial automation equipment are producing their own devices to fill this market, it can be difficult for engineers to choose the best solution for their plant and application. As industrial machinery often has a long lifespan, for example, a motor control centre can be expected to last for twenty years with the correct maintenance, many plants will be faced with this dilemma each and every time they choose to purchase new equipment.

Universal systems
True plug and play technologies are able to integrate with equipment from all vendors, eliminating any integration headaches and potential issues. They can also deliver a quality and performance that matches plant requirements exactly.

Although the concept of true, open, plug and play technologies might sound idealistic to many, it is a growing trend for many manufacturers of industrial automation solutions, such as intelligent drives and remote monitoring software.

Experienced and independent systems integrators such as Boulting Technology are experts at recommending the best system for a plant’s unique requirements and capabilities. This includes ensuring the seamless integration of plug and play, out-of-the-box systems while retaining the cybersecurity and tried and tested processes from the existing system.

Integration
As plants are constantly being upgraded and technology is evolving, the choice of products, services, software and hardware is becoming ever more complicated. Retrofitting existing systems with new sensors and communication software is, therefore, becoming more popular each year, as it is often a far cheaper solution. However, even within the retrofitting sector, vendor lock-in can be an issue.

The choice to retrofit plug and play technology, which requires less complex integration and user training, can continue to ensure cybersecurity through consistent protocols and firewalls. This is proving to be the best solution for many plants as a means of lowering costs associated with industry 4.0.

Retrofitting cybersecurity

In 1982, long before a cybersecurity threat to control system networks was widely recognised, a Trojan horse attack on control system software reportedly caused a huge explosion in a Siberian gas pipeline. Even now, many systems that have been retrofitted for compatibility with the Industrial Internet of Things (IIoT) are not well protected. 

Here, Robin Whitehead, strategic projects director at systems integrator and industrial networks expert Boulting Technology, explains the top considerations to ensure cybersecurity when retrofitting a system. 

Connected devices have led to an increased value on data from real-time monitoring, as well as the creation of initiatives, such as the smart grid, digital oilfield and smart asset management in the water industry. However, these new technologies and applications have also led to a rise in potential security risks within a plant’s network. 

Because very few companies find themselves able to build a new facility from scratch, many plant managers and engineers are choosing to retrofit existing systems with smart sensors and communication packages to take full advantage of the benefits of IIoT.

Many systems such as motor control centres (MCCs) and programmable logic controllers (PLCs) have an expected lifespan of decades and were originally designed to operate in isolation during a time of low cyber-attack risk. Connected devices can create vulnerabilities if substantial security systems aren’t in place.
 
Threat
Just one weak spot in a plant, such as an unprotected PLC can leave an entire network vulnerable to cyber-attack, especially as there are currently no regulations or clear rules about how these networks should be protected.

Research agency Gartner estimates that more than 20 per cent of enterprise security attacks will involve the internet of things (IoT) connections by 2020 and it is safe to assume that many of these attacks will use weak points such as improperly secured MCCs and PLCs to gain network access.

The Siberian pipeline attack is just one example of the devastating effects of control system vulnerabilities.

Attack
If a vulnerability is present, an insecure network can allow a threat such as a self-replicating worm to quickly become widespread throughout the facility. 

Legacy systems typically worked on closed, proprietary communication protocols and the migration to open protocols including TCP/IP means security flaws are likely to be found quickly and patched before potential attackers discover the risk. When connecting a legacy system to an open protocol security, patches can be vital in reducing potential cyber-attacks, however many manufacturers forgo their roll out due to high costs and concerns about potential downtime.

Just one missed patch can make it impossible to ensure a legacy system is protected.

Preventing vulnerabilities
Retrofitting existing equipment is the ideal way for many plants to take advantage of IIoT, but care must be taken when implementing older technologies into networks. Continual risk assessments are essential to determine potential points of attack and take all connections into account, predicting the worst-case scenario of a security breach. 

Boulting Technology has a thorough understanding of industrial cybersecurity and works closely with partners to advise plants on the best way to improve cybersecurity for their unique network. 

For a few plants, a complete overhaul of network security may be necessary, for example updating a protocol to one with continued security patches. However, the majority of plants will find that installation of additional software, security patch updates or a top-down study of network connections will be sufficient to bring cybersecurity to the necessary levels.

Cybersecurity is an ongoing concern for any plant as the threat of cyber attack is growing year-on-year and is now significantly higher than during the Siberian pipeline attack in 1982. Additional care must be taken when integrating legacy systems into existing networks. 

Choosing the right critical power supply

Today, more than 3 billion people live in cities and the urban population of the planet increasing constantly. This means a growing demand for electrical power and more complex requirements for buildings and manufacturing facilities. Add strict energy standards to the equation and the process of identifying the right critical power supply for individual applications becomes exceedingly tricky. Here, Pat McLaughlin, Boulting Technology’s Operations Director, discusses what companies should keep in mind when choosing a switchboard.

Fault capacity and ruggedness
Before commissioning a low voltage switchboard, consider what kind of external fault you can expect to have in the application. Usually this means choosing a fault rating higher than the maximum supply capacity. The rule of thumb is: fault rating = (transformer VA /700) * 20. This way, your system should be safe even in the event of an external fault.

Boulting Power Centre

Another thing to consider is the product’s lifespan. Switchboards generally have relatively long lives and can last anywhere between 25 and 40 years, perhaps even more if you treat them right and ensure the regular maintenance they deserve. However, this also means they need to be rugged and durable, so they can withstand the occasional knock and abuse life throws their way.

Location and security
Industry has a tendency to leave the electrical room layout to the very end of the building design and adapt it to suit whatever space is left over. Try to avoid this approach if you can.

Ideally, you want your electrical room to be spacious and well ventilated. If possible, there should be enough space to allow repair and replacement work to take place as smoothly as possible. Switchboards are only installed once, but there’s a good chance you will need to add cables or modules as time goes by. Devices may have shrunk, but the laws of physics and the size of cables haven’t changed.

Access to your building’s power centre boards should only be granted to authorised personnel, rather than allowing just anyone to walk in and out. Ideally, the switchboard should be located in a secured room, out of the way, so visitors don’t just stumble in while looking for the rest rooms. In addition, electrical gear is a tempting target for thieves, so it’s important to protect it accordingly from malicious attacks or vandalism.

Futureproofing
Because of their long lifespan, switchboards should be designed to last a few decades. One way of future proofing a low voltage assembly is by using a modular design. There’s a chance that as you grow, you will require more capacity. You can easily achieve this by putting a bus coupler on the end, so you can extend and modify the switchboard without shutdown. Modularity also means that if a section of the power centre breaks down it can be easily replaced without having to turn off the whole thing.

Speaking of growth, another thing you might need if you want your switchboard to be future proof is a few spare distribution and motor control feeders. They might add to the final cost, but they might also be a lifesaver a few years down the line. You can’t predict the future, but you can make it easier for those who follow you.

Keeping it simple
To make sure sources can’t be cross-connected, even if the electrical control fails, all the switches should be mechanically interlocked. Interlocking switchgear ensures personnel are safe and equipment is operated according to the correct procedures.

Labelling in large switchboards can be very confusing, so colour coding is a good way of keeping track of supplies. Sometimes special symbols can also be used for multiple sources of supply, but colour coding is the simplest and best method. It offers an ‘at a glance’ view of the system and minimises the risks of mistakes.

Very few switchboards these days will operate critical processes manually, so remote signalling and switching is something you should consider when choosing a switchboard. It’s important to make sure that if the main power goes down in the middle of the night, or over the weekend, the generator needs to be on and fully functional.

Testing
Speaking of generators, you need to ensure that you test them regularly using a load bank. You should design the switchboard in such a way that testing is easy; otherwise excuses will appear and testing will be delayed. Make sure this doesn’t happen and you won’t be left in the dark when the power goes out. Switchboards need constant attention to always be at the top of their game.

These are just some of the main things to consider when deciding the requirements for low voltage switchboards. It can be a difficult process, but luckily help is never too far away. To find out more about what options are available for your low voltage assembly, get in touch with Boulting Technology on +44 1925 720 090.

Collapsing architecture in infrastructure

The internet has a lot to answer for. Think about your job and how it would be different without the global system of computer networks we know as the inter-super-highway. Some of you might not even have a job without the internet. The information technology research and advisory company Gartner predicts that by 2020 there will be 25 billion industrial and commercial connected devices in use. Here Nick Boughton, sales manager at Boulting Technology discusses how greater connectivity is changing infrastructure.

Collapsing architecture is impacting
 industrial control systems

Collapsing architecture in an automation environment is a fairly new term that refers to the changing way in which systems in a factory communicate with one another. Systems in a plant are segregated into layers - from hardware level on the plant floor through to enterprise resource planning (ERP) computer networks in the office.

Traditionally, each layer of the factory worked on different networks; information from the factory floor was kept away from the office network and vice-versa. This was partly due to security and partly because raw data from sensors and actuators wasn't thought to be particularly valuable to the overall process.

However, in the modern age of manufacturing where margins are tight and everybody is looking for an edge, data can be collated and analysed to better understand factory processes and maximise efficiency.

With a new emphasis on quality and quantity of data, all layers of the factory are starting to communicate with one another. This means traditional network architecture in factories is starting to collapse, giving way to a new overarching, more fluid transfer of information. Industry calls this new level of interconnectedness the Internet of Things (IoT).

Whereas before, PCs on the corporate network couldn't access raw data from SCADA or hardware level, now information can be retrieved through secure access to different network cells.  There is a definite trend, not just for more data, but for more intelligence and this is spreading beyond the factory floor.  

Infrastructure is no longer publically owned. Like electricity and gas before it, water supply has become commercialised and understandably, there is now more pressure to turn a profit.

With this in mind, the factory model of collapsing architecture is starting to be seen in utilities. Competition is driving companies to look at their systems and ask how they can make them more intelligent.

The more data collected in infrastructure cells like pumping stations, the more likely it is to identify useful information. All this data can be collated and analysed to offer better insight and make more informed decisions that result in more profitable outcomes.

For example, let's say a supervisor at a pumping station turns on a pump to fill a reservoir upon arriving to work in the morning. The reservoir fills and the supervisor turns the pump off, job done. However, if you collect data at each step of this short process, certain questions arise.

Is this a peak time of day when the electricity needed to power the pump is more expensive? Can the reservoir wait to be filled during off-peak time? Does the reservoir need to be completely full or is it more efficient to only fill it to 75 per cent capacity? All this information can be processed to form more efficient results.

The IoT has brought about the collapsing architecture model with a view to improving efficiency by making better, more informed decisions. The end goal is to equip industrial computers and control systems with decision-making abilities. This allows the supervisor to concentrate on tasks that require more skill that intelligent automation can't muster...yet.