Understanding Industrial Ethernet Solutions in Grain Handling Facilities

In today’s episode of the Dust Safety Science podcast, Brian Knapp, Vice President of Electronics Division at 4B Components, discusses the role of industrial ethernet solutions in grain handling facilities.

Brian manages the electronics division at 4B Components, which primarily focuses on the hazard monitoring sensors and controls for grain elevators and other facilities with combustible dust (or facilities that even don’t have combustible dust to improve their preventative maintenance).

What Challenges Exist at Sites With Multiple Sensors?

Brian recalled one case study titled “Flour Milling: Best Way to Reduce Costs on Electrical Labor and Materials.” It covered a site in Oakland, California, with 19 bucket elevators, each of which was typically equipped with nine sensors. These sensors include bearing temperature sensors, belt alignment sensors, and one speed sensor.

The challenge is to wire all these sensors back to a processing location to make decisions on alarms and equipment shutdowns. With 171 sensors, routing them to one location involves a lot of conduit, wires, and labor, which relates to reducing costs on electrical labor and materials. Such a large facility generally uses a control system called a PLC (Programmable Logic Controller). They might also use SCADA systems, which are similar but vary in distribution.

Monitoring 171 points with one system requires pulling wires back to it, having input cards for the sensors, and incurring costs for wiring, installation, PLC hardware, and rack space. The goal is to reduce installation costs without compromising data collection speed, and Industrial Ethernet is a common solution for remotely transmitting data back to a central processor like a PLC.

What is Industrial Ethernet?

Industrial Ethernet uses the same Ethernet technology found in computers and cameras, typically employing Cat5 or Cat6 cables connected to Ethernet switches. The difference lies in the protocols used for industrial applications, which are specific to the type of PLC (Programmable Logic Controller) being used.

In the United States, the most common PLCs are manufactured by Rockwell Automation under the Allen-Bradley brand, which use a protocol called Ethernet/IP. In other parts of the world, Siemens is a major player in automation, using a protocol called Profinet. Schneider PLCs use a protocol known as Modbus TCP. These three primary protocols are supported by the industrial Ethernet nodes we manufacture.

These nodes use Cat5 cable with an RJ45 connector and can collect data from up to 16 sensors. Each node has its own IP address, allowing individual sensors to be identified and their data transmitted to the PLC in fractions of a second. The automation team or programmers can then read temperatures, speeds, and other data, triggering alarms in the PLC if certain thresholds, such as a temperature exceeding 140°F, are met. This distributed form of data collection via remote Ethernet connection reduces installation costs compared to traditional wiring methods.

Before the advent of industrial Ethernet nodes, other systems existed, including those from various manufacturers that offered proprietary communication protocols acting as gateways to the PLC. However, automation professionals often avoid these “black box” solutions due to their potential for additional points of failure and complexity. Using industrial Ethernet for direct communication provides a more reliable and straightforward approach.

Industrial Ethernet nodes can be placed locally near the sensors, which are often spread throughout a facility, including bucket elevators that could be hundreds of feet apart. This setup reduces the amount of sensor wiring needed. Ethernet’s flexibility allows for network structures such as star patterns, enabling branching with Ethernet switches. This flexibility and built-in troubleshooting capabilities make Ethernet a robust communications protocol with significant isolation, ensuring that a problem with one device is unlikely to affect the entire network.

Over the years, Ethernet has become the standard for distributed systems. In the past, other protocols were used. For example, 18 years ago, Ethernet communications were not common in these systems. Instead, devices like Allen Bradley’s solution used a daisy chain communications protocol. While daisy chaining reduces wiring costs and can be effective, Ethernet’s advantages have made it the preferred choice in modern systems.

What Else is Being Controlled?

Brian explained that a smaller mill built in the Midwest a few years ago focused on incorporating the latest technologies, including an Ethernet infrastructure. The electrician for the project reported running about 15 miles of Ethernet communication cable, indicating that almost everything in the facility is Ethernet-based. Specific details of the setup include Ethernet nodes and smart MCCs (Motor Control Centers), where motor contactors in the MCC room are Ethernet-based. This setup allows equipment to be started and stopped over Ethernet rather than with physical buttons, and it provides extensive data from the contactors, such as current, voltage, and temperature measurements.

The facility also uses HMIs (Human Machine Interfaces) for graphical displays that communicate with the PLC over Ethernet. These touch screens allow operators to view temperatures of bearings and rub blocks, and potentially monitor bin levels. IP-based cameras are likely installed throughout the facility to monitor areas like the truck dump or rail loadouts. Scales measure the weights of trucks entering and leaving the facility, and there are many other processes where grain is turned into flour. This includes numerous machines measuring pressures for pneumatic fans and other critical parameters.

Brian added that this large co-op had multiple facilities, each built at different times, leading to a variety of monitoring equipment standards. Some facilities had up-to-date monitoring systems, some were outdated, and others had none at all. The co-op aimed to standardize its monitoring technology across all facilities and sought a manufacturer capable of meeting diverse requirements. Some facilities had PLCs, while others were entirely manually controlled, necessitating different approaches.

The team walked through each facility with the co-op to determine their specific needs, understanding that not all upgrades would be implemented simultaneously. Although the specific facility in the story did not install industrial Ethernet nodes, other facilities did. This particular facility used a standalone watchdog system with Ethernet capabilities. The team also had the capability to collect data and push it to the cloud, allowing for logging and trending of bearing temperatures, belt speeds, and other metrics, as well as setting up email alerts and alarm logs.

During the commissioning process, the team assisted on-site, emphasizing the importance of thorough testing both during and after installation. Testing ensures the system’s longevity and reliability, as systems need regular maintenance and checks to prevent issues from arising over time. The team encouraged managers and maintenance staff to work closely with equipment manufacturers to ensure they have the necessary tools for proper sensor testing, such as heating up bearing temperature probes and producing pulses for speed sensors.

While on-site, the team provided additional training and demonstrated their cloud portal, Hazardmon.com. During a live display review of one of the conveyors, they observed a bearing’s temperature trend line increasing. The temperature continued to rise, prompting a manager to call a maintenance worker. The maintenance worker used a grease gun to lubricate the bearing, and the team watched the temperature trend line drop significantly with each application of grease, demonstrating the system’s value. This real-time monitoring and immediate action showcased the practical benefits of the Ethernet communication and cloud portal, proving the system’s effectiveness beyond just a sales pitch.

Industrial Ethernet is a Proactive Measure

While the systems are designed to shut down equipment to protect the facilities, the main goal is to increase uptime and reduce downtime by detecting issues early. This allows for corrective action or planned preventative maintenance, rather than facing unscheduled downtime. The sooner a problem is identified, the less downtime the facility will ultimately experience.

For smaller facilities, there is a noticeable increase in the use of programmable logic controllers (PLCs) to control operations. This trend predates the pandemic and stems from the general challenge of finding skilled workers, particularly in the agricultural industry. Historically, there were more experienced personnel available for maintenance roles, but now there are fewer workers with less experience. This shift has created a greater need for automation and continuous hazard monitoring to ensure safety and efficiency.

Automation, including industrial Ethernet for sensor information, enhances control and monitoring capabilities. Smaller facilities can benefit from these technologies, such as hazard monitoring through cloud portals like Hazardmon.com, even if larger corporations face IT approval challenges. These smaller facilities can use trend lines to detect issues like overheating bearings without needing to develop the technology themselves, as it is costly and complex.

Facilities without PLCs can still use standalone systems for alarming, automatic equipment shutdowns, and data push to the cloud. This enables facilities of all sizes to utilize Ethernet for internal communications and data gathering, either with their own PLCs or with standalone systems, ensuring comprehensive monitoring and control.

Fewer personnel mean workers are more spread out, making centralized monitoring crucial. With centralized systems, multiple facilities can be monitored from one location, allowing a person to check bearing temperatures across different sites. This flexibility is valuable for companies of all sizes.

As automation becomes more prevalent, industrial Ethernet is considered the best solution, especially when hardwired with Cat5 cables for reliability. Hardwired systems avoid issues such as trucks blocking line of sight or wireless interference. While wireless technology may become more reliable and cost-effective in the future, current reliability concerns make hardwired Ethernet the recommended choice, particularly for critical hazard monitoring to prevent ignition sources in grain dust environments.

Conclusion

The increasing adoption of programmable logic controllers (PLCs) and Industrial Ethernet in facilities of all sizes highlights the essential role of automation and continuous monitoring in today’s operational landscape. Technologies like industrial Ethernet nodes and cloud-based monitoring platforms provide robust solutions for ensuring safety, reducing downtime, and enhancing overall efficiency.

As automation continues to evolve, facilities that invest in these technologies will be better equipped to maintain uptime, ensure safety, and optimize their operations. Embracing Industrial Ethernet and advanced monitoring systems is not just a step towards modernization but a strategic move to future-proof facilities against the challenges of an ever-changing industrial landscape.

If you would like to discuss further, leave your thoughts in the comments section below. You can also reach Brian Knapp directly:

Website: https://www.go4b.com/usa/

LinkedIn: https://www.linkedin.com/company/4b-components-ltd/

Email: [email protected]

If you have questions about the contents of this or any other podcast episode, you can go to our ‘Questions from the Community’ page and submit a text message or video recording. We will then bring someone on to answer these questions in a future episode.