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.

Protecting utilities

Minimising cyber security threats on industrial control systems 

In 2017, the UK Government proposed the implementation of the Security of Networking and Information Systems (NIS) Directive,  with the aim of improving the security of essential services such as water and energy. Should providers fail to protect their systems, a £17 million penalty could be enforced. Here, Nick Boughton, sales manager at leading industrial systems integrator Boulting Technology, discusses why it is important for utility providers to protect themselves from cyberattacks. 

Plant managers within utility companies are now demanding more from their industrial control systems (ICS) to deliver operational improvements through smarter, information-enabled machines. As a result, the domains of IT and OT are converging and becoming increasingly connected as many ICSs are now overlapping with enterprise systems to provide accessible, secure information that is visible across organisations. With these increased benefits, however, comes a rise in additional security risks.

Typically working on closed, proprietary communication protocols, the migration to open protocols can present several issues, including unpatched software and hard-coded passwords. Robust systems, such as PLCs, were built to last before network connectivity was even considered.

When connecting a legacy system to an open protocol, it is essential that it is done safely and securely. Security patches can be vital in reducing potential cyber-attacks, however many manufacturers forgo their roll out as the associated costs can be high. Every missed patch makes it much harder and more expensive to ensure a legacy system is protected.

It is these risks that the Joint Committee on the National Security Strategy discussed in late May 2018. If ICSs are not protected properly within the utility sector, then it is not just breaches of the GDPR we should be worried about, but the supply of water and energy.

There is no one size fits all solution to protecting industrial control systems and it shouldn’t just cover the protection of a single system. IT and OT convergence means a holistic approach to industrial security should be taken, extending from a single enterprise system, to the people, processes and technologies within a plant.

In its 2016/17 report, the cyber threat to UK business, the National Cyber Security Centre (NCSC) suggested cyber security is most effective when integrated with risk management procedures.

To give maximum protection against cyber-attacks, a plant must have a robust security framework that encompasses people, processes and technologies. Our alliance with Netbuilder, a leading provider of software and IT consulting services, allows us develop and implement seamless solutions across IT and OT, which have traditionally been managed separately.

While having the latest firewalls, antivirus and intrusion detection software is important, it is redundant if staff are not trained properly. Working with an experienced supplier, such as Boulting Technology, will aid in developing one such framework.

Without a strong commitment to security, manufacturers will fall victim to the many pitfalls faced by open protocols.

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. 

Preparing for the future

Exploring the World Economic Forum’s Readiness for the Future of Production report 

In January, the World Economic Forum (WEF) launched its first Readiness for the Future of Production report, which revealed Britain to be one of just 25 countries in a positive position to benefit from the fourth industrial revolution. Here, Nick Boughton, sales manager at leading systems integrator Boulting Technology, explains the key findings of the report and what it means for UK manufacturers. 

Some of the world’s richest and most powerful people, including Donald Trump, Justin Trudeau, Theresa May and Emmanuel Macron took to the snowy Swiss town of Davos in January for the WEF’s annual meeting. Since its humble beginnings in 1971 as a management forum, the event now sees over 3,000 of the world’s leading business, financial and political figures discuss a variety of topics that can aid in improving the state of the world.

As part of this year’s meeting, the WEF launched its Readiness for the Future of Production report, which details a new framework assessing how well positioned global economies are to benefit from Industry 4.0.

The framework is made up of two key components: structure of production, which measures a country’s scale of production and drivers of production, which looks at the key enablers that allow the country to capitalise on Industry 4.0.

Japan was identified as leading the way in current baseline production, while the US is best positioned to capitalise on Industry 4.0 in order to transform manufacturing production systems.

How ready is the UK?
While the UK has a long history of manufacturing, in recent years the industry share in its economy has declined from 25 per cent in the 1970s to less than 10 per cent in 2017. This decline in market share has had a significant impact on jobs and indeed the number of manufacturing facilities around, with many shutting down due to production being cheaper abroad. 

Despite the fall in market share, the UK has a strong ability to innovate and is leading the way in high-tech manufacturing industries such as aerospace and pharmaceuticals. This has led to the creation of the smart factory, where machinery and equipment are able to improve processes through automation. Between January and October 2017, the UK aerospace industry grew by a rate of 9.8 per cent, making it the fastest growing aerospace market among G7 countries.

The pharmaceutical sector is also set to strengthen its position following a period of decline. The recent investment by Accord Healthcare, which opened a state-of-the-art factory in Fawdon earlier this year, creating between 350 and 500 new jobs, is one of many examples of growth in the market. 

The rise of the smart factory has resulted in a definite skills gap, however, with many manufacturers not having appropriately trained staff to capitalise on the benefits of technologies such as robotics. The UK Government has put plans in motion to tackle this issue with the launch of the Made Smarter review, which looks at three of the industry’s key challenges: leadership, adoption and innovation.

Drivers of production
In order to support the development of the global manufacturing industry, the WEF’s report identified six drivers of production that represent the factors and conditions that need to be met to capitalise on Industry 4.0 technologies. These drivers are technology and innovation, human capital, global trade and investment, institution framework, sustainable resources and demand environment.

Drivers of particular importance for system integrators are technology and innovation and human capital.

Technology and innovation
Emerging technologies such as edge computing, digital twinning and virtual reality are reliant on a strong technology infrastructure. While the UK is a leader in innovative technologies, many manufacturers fall at the first infrastructure hurdle due to a lack of connected devices and the ability to effectively analyse and make use of the data produced by their equipment.

With many systems, such as motor control centres (MCCs) and programmable logic controllers (PLCs) having a long-expected lifespan, older devices do not have the capability of connecting to a wider network unless retro-fitted with the appropriate sensors and communication packages.

Once connected, digital security and data privacy can become an issue. To counter this, manufacturers must have a strong cybersecurity policy in place when adopting new technology.

Human capital
People are often critical of transforming production facilities. If the workforce doesn’t evolve, a business has no hope of changing its operations. The introduction of new technologies has led to a change in the skills required by manufacturers, with many struggling to adapt and therefore missing out on the benefits of the Industrial Internet of Things (IIoT).

In the coming years, there will be a further shift in production from labour-intensive roles to those that are more knowledge and skills based. With this shift, fears of job losses have risen once again. According to a YouGov survey, 13 per cent of employers think that more than 30 per cent of jobs will become automated in the next 10 years. While some jobs will be managed by industrial digitalisation technologies (IDT) such as robots, many new roles will be created that are more skills based.

With this in mind, the UK Government’s Made Smarter review will be key to ensuring the manufacturing industry is fully equipped to benefit from Industry 4.0. As new roles are created, the training of new staff and re-training of existing employees will be vital in addressing the skills gap created by the evolution of technologies.

Boulting Technology is tackling the skills gap head on with ongoing training and development for all staff and a robust apprenticeship programme. As new technologies are introduced, it’s important that staff undergo relevant training to effectively incorporate new technology into their work. All Boulting Technology employees are encouraged to undertake continuing professional development (CPD) and are supported by the business to do so.

The Readiness for the Future of Production report and the Made Smarter review will play significant roles for those looking to drive innovation through Industry 4.0. For manufacturers to truly benefit from IIoT technologies, they must transform their internal infrastructure, which includes staff capabilities. By not doing so, the UK’s position in the WEF report will no doubt slip in years to come.

Predicting the future

The fourth industrial revolution is well underway and as state-of-the-art technology drops in price, many more industries are benefiting from smart factories. As a recent PwC survey found 72 per cent of companies expects to achieve advanced levels of digitisation by 2020, the reach of these technologies is only set to increase in 2018.

Here, Nick Boughton, sales manager at leading systems integrator, Boulting Technology shares his predictions for 2018.

In November, the UK Government announced that 2018 would be the Year of Engineering. This coupled with the launch of the Government’s Industrial Strategy and Made Smarter Review has signalled a major vote of confidence in the sector as it pledges to help make the UK a world leader in the Fourth Industrial Revolution by 2030.

With Industrial Digital Technology’s playing such a significant role in the transformation of the sector, what should manufacturers be investing in?

Real applications of virtual reality
Virtual reality (VR), which digitally simulates a product or environment and augmented reality (AR), where the digital product or information is projected on to a real-world background, have traditionally been consumer-focused applications, aimed mostly at gamers.

However, with equipment such as the Microsoft HoloLens now being aimed purely at business applications, this is changing.

Boulting Environmental Services uses virtual reality to provide its clients with a unique opportunity to immerse themselves in their projects, develop designs more clearly prior to beginning construction work and reduce mistakes.

Virtual reality will become prominent during the design of a facility and it could even have applications for building information modelling (BIM). Inputting computer-aided design (CAD) files into a VR application can allow the designer, engineer and client move around the product and facility, viewing it under a different light without the need to produce expensive prototypes. VR also has the potential to revolutionise training, particularly when working in hazardous environments. Engineers can explore and manage a range of scenarios without any risk to themselves or equipment.

Maintenance is where augmented reality comes into its own. AR can instantly provide important information to maintenance engineers wearing AR headsets while allowing them to keep their hands free.

For example, when combined with remote monitoring and dashboard user interfaces, the status of a drive or motor control centre can be visualised next to the system in question. This type of technology is already being employed by companies with multiple sites, allowing for the comparison of key performance indicators (KPIs) between plants, learning from one another to improve process efficiency and asset lifespan.

Similarly, when combined with a risk-based maintenance schedule such as Boulting’s BRISK, each piece of machinery can be colour coded according to the risk it poses to the plant.

The rise of artificial intelligence
Machine learning is a concept that has been around for decades, where the computer doesn’t rely on rule-based programming but instead operates using algorithms that can adapt and learn from data.

Closely related to this is artificial intelligence (AI), a branch of computer science aiming to build machines capable of intelligent behaviour.

One of the major benefits of AI is advanced data analysis, where data is collected, stored and analysed automatically.

Dependant on the results of the analysis, processes can be automatically altered, increasing productivity, reducing costs or even preventing production downtime. Combined with trend prediction and predictive maintenance schemes, efficiency and yield rates can be greatly increased across a manufacturing plant.

Smarten up your factory
Legacy systems were traditionally designed to operate in isolation and are often unable to connect to the wider network and the internet. However, since the advent of Industry 4.0, many plant managers are keen to connect systems and take advantage of the benefits of the Industrial Internet of Things (IIoT), including enhanced data collection, interpretation and use. The answer for many is to retrofit their systems to enable IIoT capabilities.

Smart sensors, data analysis systems and connectivity to the IIoT are just some of the benefits promised by the range of retrofitting options on the market.

The popularity of retrofitting existing equipment with these technologies using a maintenance budget is only going to increase. As equipment wears and requires replacement, the best choice for many will be a smart sensing motor or motor control centre which can connect to IIoT.

The introduction of Industry 4.0 technologies has left no stone or industry untouched over the past few years, particularly given recent price drops. 2018 is shaping up to be the year where new and exciting technologies such as VR and AI make their way onto the plant floor, making it truly a factory of the future.

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.