One of the most important advances in batch integral quench (BIQ) furnace systems has been the development of innovative control systems. Many BIQ manufacturers have developed their own highly sophisticated and cutting-edge control systems.
This Technical Tuesday, we explore one such system written by Daniel Hill, PE, sales engineer at AFC-Holcroft. This original content article was originally published in the February 2021Air and Atmospheres, the IQ Edition.
Daniel Hill, PE Sales Engineer AFC-Holcroft Source: AFC-Holcroft
With continuing advancements of smart devices, integrated controls systems, and the Industrial Internet of Things (IIoT), we have at our fingertips an abundance of data, both the traditional and newly developed. How to convert that data into useful information, and more importantly how to leverage that information into day-to-day operations to reap the benefits, becomes the difference maker in a competitive landscape.
Recognizing these trends, AFC-Holcroft has built upon a suite of software modules that includes Remote Diagnostics™ to also offer Maintenance Module™ and Calibration Mode™. All three modules are in commercial service having been integrated with BatchMaster™ controls system features on Universal Batch Integral Quench (UBQ) furnaces. End-user response and adoption have been positive with new synergies and feedback leading to ongoing enhancements. In this article, we will discuss how these advancements are affecting the future of furnace diagnostics and some examples of their benefits in many day-to-day situations.
Dynamic Furnace Calibration & Diagnostics
Perhaps the most interesting of the three modules is the Calibration Mode, a patent-pending diagnostics software designed to dynamically test furnace operation for verification of proper functionality over a wide range of subsystems and devices. Notably, furnace and quenchant heating/cooling thermal loads are strategically cycled for response monitoring of typical production needs. Likewise, furnace atmosphere is cycled for response and stability. Additional systems and metrics such as agitation attributes, tray motion and positioning, time to quench, and elevator operation are activated and evaluated.
Once the calibration cycle is complete, the data and responses are compared to original commissioning data and design thresholds to generate a time-stamped diagnostic report with straightforward pass/fail results. With this module, the operator can ensure proper operation at a moment’s notice without additional external testing devices and have the data available to back it up.
It was designed to integrate optional device packages to elevate its diagnostics capabilities exponentially by targeting efficiency and optimization of operation including:
Combustion efficiency monitoring
Vibration monitoring
Power consumption monitoring
Process Troubleshooting
As its base premise, this module was created as a means for operators to proactively verify that the furnace is both fully operational and responding as designed. But what happens if it is not? Calibration Mode can be initialized at any time for deeper analyses by first reporting the current status of subsystems and devices and then for further comparison against initial commissioning data or cumulatively against any previous calibration iterations, making it a powerful tool for rapid diagnostics.
With the auto-generated reports and comparison tools in hand, operators or maintenance team members can pivot directly into troubleshooting any deficiencies identified for quick resolution. Once more, a follow-up can be run to ensure the deficiency is corrected after making appropriate adjustments or repairs. This saves valuable time and resources, improves availability, and likely increases profitability.
Calibration Mode™ Screen Source: AFC-Holcroft
Compliance with Industry Specifications
Whether following automotive (CQI-9), aerospace (AMS2750), military, energy, or other specifications, universal themes requiring the user to implement regular assessments, surveys, and the monitoring of the process equipment are paramount. Today, the Calibration Mode is being used to supplement these efforts in a number of ways:
Creating reports with Calibration Mode for job audit in annual Heat Treat System Assessments (HTSAs)
Producing objective evidence for process equipment validation before and after a major rebuild or modification
Collecting and analyzing data over time and reacting to it
Running with TUS as another layer of equipment verification
Running with Quench System Monitoring as another layer of verification
PPAP, Control Plan, & PSW Inclusion
The production part approval process (PPAP) must be a collaboration between the customer and heat treater to ensure a clear understanding of all elements before, during, and after the processing. Calibration Mode can be utilized as a verification tool initially when processing parts for a PPAP to document the furnace capability and that it is meeting original OEM specifications. If repair or rebuilds are required while that PPAP is still valid, Calibration Mode can be run to demonstrate the equipment in operational condition on a Part Submission Warrant (PSW). Moreover, Calibration Mode can be incorporated into control plans both as a control method for ongoing production and also as part of a reaction plan to diagnose nonconformance.
Dedicated Equipment Vs. Changeover of Equipment Running Multiple Processes
A major benefit of batch processing equipment is the inherent flexibility it offers–especially to commercial heat treaters who are serving multiple customers with many different processes. Often customer specifications for heat treating include clauses preferring dedicated equipment with strict allowances on changeover of equipment. Typically, changeover of equipment for multiple processes requires customer personnel to review and approve the heat treater’s changeover procedures and must include verification prior to start of production (including atmosphere). This changeover process must be documented in the heat treater’s process control plan. Consider running Calibration Mode at changeovers as a means to consistently verify conditions and provide documentation to the benefit of all involved.
Intelligent Preventative Maintenance
Maintenance Module™ also takes advantage of the latest advancements. This module is designed and pre-programmed to include the OEM recommended preventative maintenance tasks based upon pre-defined intervals, sometimes utilizing conditional statements, or where appropriate, predictive algorithms based upon operating time, temperatures, and number of cycles. This database of tasks and report queries provides an intelligent roadmap for the preventative maintenance of the furnace. As such, maintenance task statuses are elevated and flagged for action complementary to accrued usage and actual conditions so that all-important resources can be prioritized and best served.
Maintenance Module™ Screen Source: AFC-Holcroft
Leveraging Diagnostics through the Cloud
Finally, Remote Diagnostics™ was conceived to increase furnace uptime and availability through the analysis of equipment performance data. Real, data-driven reliability and maintainability (R&M) information supports continuous improvement efforts. As a first step, the abundance of data delivered through the IIoT is aggregated to effectively parse, diagnose, and highlight operational inefficiencies.
Next, virtual conference sessions are led by AFC-Holcroft personnel to collaborate with users on best practices, identify training needs, aid in knowledge capture, and provide optimization plans moving forward in a classic continuous improvement cycle.
Interestingly enough, it has become a source of synergy for continuous improvement efforts by allowing us to better understand users’ needs and incorporating them into designs and equipment of the future.
Addressing important day-to-day situations, Calibration Mode, Maintenance Module, and Remote Diagnostics are helpful tools for the forward-thinking BIQ furnace operator.
About the Author: Daniel Hill, PE, is a sales engineer with AFC-Holcroft, based in Wixom, Michigan. AFC-Holcroft is a leading North American manufacturer of industrial furnace systems used in the heat treatment of ferrous and non-ferrous metals.
State of Industry 4.0 in the North American Heat Treat Market: What’s Being Done and Who’s Using It?
What is “Industry 4.0” and how is this new technology being used in the heat treat industry? Industry experts spoke with Heat Treat Todayabout their involvement with this cutting-edge application of technology. To learn how you can implement Industry 4.0 at your plant, read what experts have to say about the problems, solutions, and the future of Industry 4.0.
In this Heat Treat Today Original Content article, Peter Sherwin at Eurotherm, AymericGoldsteinas at Ipsen, Robert Szadkowski at SECO/WARWICK Group, and Dan Herring at The HERRING GROUP, Inc. bring varied perspectives as they tackle this topic.
“I think IoT should be better applied – period!”
– Peter Sherwin, Global Business Development Heat Treatment Executive, Eurotherm
Industry 4.0 and “the internet of things” (IoT) were hot topics in the crammed online chatrooms of this year’s heat treat events. But exactly what are these technologies in the world of heat treat? What are the current applications that three leaders in Industry 4.0 have applied? What are some problems and solutions that this new tech brings? And lastly, what is the future of Industry 4.0?
This article will begin by explaining and defining a few prominent technologies before answering each of these questions. Then, read a few thoughts from The Heat Treat Doctor® as you think about application to your heat treat process.
What Is It and Why Does It Matter?
Basically, the term “Industry 4.0” refers to the Fourth Industrial Revolution. See the chart for a breakdown of major topics of the first three industrial revolutions.
Infographic of the four industrial revolutions. Source: Heat Treat Today (images ref. 11)
The idea of new communication is sometimes referred to as cyber-physical connections. This is occurring right now! For example, a sensor (cyber) can monitor a furnace (physical) and send information about the furnace’s conditions to a central data sorting location (connection) for a human to synthesize and respond. The Fourth Industrial Revolution – Industry 4.0 – refers to how the communication between the physical world and the digital world are seamlessly connected.
Click the image to learn more
A key feature of Industry 4.0 is the internet of things (IoT), but other technologies like artificial intelligence (AI), augmented reality (AR), virtual reality (VR), and machine learning also play a part. Let’s define a few of these Industry 4.0 terms that you will see later in the article:
IoT: refers to the physical networking of objects via internet-supported software. Similarly, the “industrial internet of things” (IIoT) refers to these systems supporting industrial purposes, like synthesizing information from furnace sensors on a central app.
artificial intelligence (AI): machines which can process and perform complex directions in a way that mimics natural intelligence.
augmentedreality (AR): digital enhancement of a real-world environment. Think of phone apps which can portray a digital overlay on a video feed, like Snapchat lenses.
virtual reality (VR): digital experience that may be interactive with the real-world environment, or completely simulated.
machine learning: an extension of AI, machine learning describes the result of computer algorithms which modify their performance based on repeated input.
While engineers have been pursuing these new applications for several years, COVID-19 has been a driving factor for businesses to pursue technical options in their daily operations due to limits on travel and physical contact.
[blockquote author=”Robert Szadkowski, VP of Aftermarket Sales, SECO/WARWICK Group” style=”1″]Remote acceptance testing is a highly requested service today. I could say that the financial rationale for such action has always existed, while the epidemiological threat has been the catalyst for change. It is a win-win action.[/blockquote]
According to Aymeric Goldsteinas, project development manager at Ipsen, customers are becoming more willing to implement Ipsen’s Industry 4.0 endeavors, even cloud-based solutions, a willingness that was not present just one decade ago. So how is the heat treat market responding?
Current Applications
We asked suppliers how they implemented Industry 4.0. What follows is how they responded.
Ipsen | PdMetrics
PdMetrics Dashboard Source: Ipsen USA
Ipsen launched a software system in 2016. The company continues to develop and improve its predictive maintenance capabilities to service many of their current customers.
Part of the system’s customer appeal, said Aymeric Goldsteinas, product development manager at Ipsen, is that it can “minimize high-cost events and maximize furnace up-time.”
This is done by using sensor technology and gathering data in their PdMetrics database, which then anticipates future furnace problems. This reduces unplanned downtime and could help heat treaters avoid scrapping loads of high-value parts.
From a consumer perspective, this IoT technology solution leads to improved part quality and part performance.
How it works: PdMetrics assigns a variety of sensors to each system in the heat treat process. For example, a quench system sensor checks vibrations, cooling motor temperature, and water temperature.
Source: Ipsen Harold Click the image to read 5 case studies on PdMetrics.
On Ipsen’s client digital dashboard via PdMetrics, Goldsteinas showed the heat treating systems depicted with a green-yellow-red gauge to portray the working condition of that system. Green indicates that the system is well-maintained, yellow indicates a system needs to be maintained soon, and red means that maintenance is needed immediately. This easy-to-use display is also an example of how Industry 4.0 technologies create user-friendly experiences and cut out excess human input.
This product was used by an aerospace manufacturer to update their systems, integrating this software with their heat treatment process. The results were noticeably increased efficiency of parts and less unplanned downtime. The company was able to schedule maintenance at off-peak hours and plan for future needs by using the platform’s ability to identify maintenance trends, deteriorating conditions, and more.
Check out the post to the side to see how a heat treater was able to save thousands to tens of thousands of dollars with PdMetrics system.
While this company has set the pace with their early adoption of IoT in the heat treat industry, it is worth noting that other companies also offer similar products.
In 2013, Eurotherm began their transition to IoT technologies.
“One of our first true cloud-based solutions focused on improving the efficiency of the calibration process,” said Peter Sherwin, global business development heat treatment executive of Eurotherm. He continued, “This system connects third-party calibration providers with their end-customers and provides an enterprise-wide web view of the calibration status (via dashboards) and access to reports. The smart-tablet app provides an easy-to-follow workflow for conducting a compliant calibration and produces an instant report along with the associated QR-code label.”
Referring to their web-based systems and use of cloud platforms, Sherwin said, “along with our parent, Schneider-Electric, we have developed a range of edge-computing solutions to allow simple transfer of data from the plant-floor to cloud-based advisors and visualization software.”
Sherwin says that their systems are being used globally. “Our enterprise calibration platform,” he shared, “is being utilized by several partner companies as well as in Schneider Electric GSC (Global Supply Chain) Manufacturing plants worldwide.”
Sherwin also noted a variety of IoT applications that Eurotherm provides:
A cloud-hosted digital services platform, EcoStruxure™ Manufacturing Compliance Advisor uses asset compliance to “reduce testing costs, increase productivity and be audit-ready with a robust scheduling and testing process.”
A system called EcoStruxure™ Machine Advisor “allows OEMs to track, monitor and fix equipment remotely.” Additionally, operators can predict and execute maintenance schedules, which improves machine availability.
On a mobile device, EcoStruxure™ Augmented Advisor combines “contextual and local information… creating a fusion of the physical, real-life environment with virtual objects.”
Case in point: “An OEM machine manufacturer in the ceramics industry helps customers reduce their energy consumption by 30% by leveraging our IoT software,” Sherwin shared.
SECO/WARWICK | Remote Factory Acceptance and Activation Tools
Remote Control Source: SECO/WARWICK
Recently SECO/WARWICK publicized the fact that they successfully conducted several international and remote factory acceptance tests. Two customers from China, one from South Korea, and one from Mexico all participated. Each customer was able to remotely approve the furnace construction and performance work of their new furnaces while the furnaces were still on the shop floor in SECO/WARWICK’s European manufacturing facility. No customer engineers were involved on-site at the factory.
Recordings from individual cameras, sensors and viewfinders were downloaded to secure servers and made available to customers. The tests were successful, and the adopted procedures guarantee the reliability and completeness of the data, according the company report.
The company has been using these technologies for “internal device supervision for at least ten years,” according to Robert Szadkowski, VP of Aftermarket Sales at SECO/WARWICK. “In our work,” he continued, “we use remote supervision tools and applications, we report overall equipment efficiency (OEE) indicators, and we conduct optimization processes in terms of batch queuing or energy factor consumption.”
Szadkowski at SECO/WARWICK remarked that for most systems, distance furnace commission is very likely. He explained, “It starts at the stage of making arrangements regarding the expected technical and technological parameters, continues throughout the production and commissioning period, and then during the warranty and post-warranty period. The participation of the customer, the end user of the furnace, in the acceptance tests is required, as is training of the operating personnel […]. There are exceptions to this when dealing with high-risk systems, but for many systems this would be perfectly acceptable.”
Still, Szadkowski noted that “this will be primarily a challenge to our ideas and internal acceptance, rather than to technical limitations.”
C3 Data | End-User System Compliance
Finally, the C3 Data application for furnace compliance is an example of an interrelated, stream-lined, digital solution that provides customers with clear, “real-time” data.
Digitizing data ahead of time integrates testing processes. The system scheduler allows compliance tests to be planned ahead of time. Digitizing the calibration data allows for technicians to scan QR codes attached to test instruments and test sensors to access that data as they test for compliance.
When compliance is tested, the results are immediate for the technician and the quality assurance manager (QAM). The technician uses a portable device to complete these tests, scanning the test instrument and the test sensor, and then inputting the stabilized temperatures from the test instrument and the furnace instrument. In twelve seconds, a technician can complete a system accuracy test (SAT); watch the video above to see the SAT Additionally, the system automatically populates paperless reports to be signed and sent to the QAM. This allows the quality assurance manager to check the reports in real time.
Similar to earlier products, a digital dashboard depicts furnace compliance data. The graphic visualizations allow users to quickly evaluate which furnaces are in compliance, and, if not, why.
Problems // Solutions
Businesses have experienced a few problems with integrating the technology. But there are solutions.
Aymeric Goldensteinas Product Development Manager Ipsen Source: padtronics.com
The first problem is data storage. Like all storage, data storage is finite, and therefore costly. The use of interrelated systems that require high volumes of data to flow between sensors and central systems necessitates investment on the front end for storing data. Additionally, having limited bandwidth to keep digital communication lines open can cause blackouts and connectivity issues. But after acquiring storage, there are practices to use that storage as efficiently as possible.
A solution that Ipsen implements to alleviate this active/working storage stress is “the frequency rule.” This rule establishes a rate of data movement to allow data to move across system memory.
A second issue is privacy/security. It is necessary that the heat treater’s product or process data is properly secured, and while the supplier has certain responsibilities to mitigate this issue, heat treaters should be aware of ways to safeguard their intellectual property. One option, which Ipsen suggests, would be to purchase a unique VPN to ensure better data security. Some companies, including Ipsen, use a stand-alone system that works independent of the PLC, which ensures proprietary data is kept private while following secure industry software standards.
A third issue is user acceptance or, simply put, how comfortable you are with 4.0 technologies. If a heat treater is not comfortable with the technology itself, then Industry 4.0-related tech can be more difficult to implement. On the flip side, suppliers — regarding all processes — must be ready and able to meet the customer’s demands for new products, as Dan Herring, The Heat Treat Doctor®, has indicated. (Ref. 5) An example of digital demands is the AMS2750F requirement that paper chart recorders be replaced with digital data acquisition systems by June 29, 2022.
User acceptance relates to the final problem: relationship with the supplier. While not a bad thing in and of itself, if your relationship with your supplier is not good, then it will be a challenge to develop an effective Industry 4.0 solution process. Be sure you develop an open, communicative relationship with your supplier so that they can offer you unique solutions for your plant’s operation.
The Future of Heat Treat
Here are some interesting applications that people in the industry are looking to with the progression of Industry 4.0:
1. Increased Servitization
Robert Szadkowski Director, Vice President of the Aftermarket Sales Segment SECO/WARWICK Source: Robert Szadkowski
Szadkowski at SECO/WARWICK emphasized that these rapid changes to heat treat systems makes it likely that the servitization — the selling of services rather than products — of the heat treat industry is likely to develop in the near future.
“I am strongly convinced,” Szadkowski wrote, “that sooner or later the servitization will cover the heat treatment industry. When looking at the potential benefits, it’s basically inevitable. The customer, user of the furnace, will be able to focus on their core business instead of worrying about the operation of the furnaces. The manufacturer of the device will be keenly interested in ensuring that its furnace works flawlessly (so that the availability is as high as possible) and brings business benefits to the user. What’s more, with a correctly prepared PaaS (Product as a Service) contract, the OEM will also be interested in improving the operating parameters of such a device after delivery.”
He continues that “Such solutions have existed in the industry for years, e.g. the Rolls-Royce model of selling aircraft engines known as Power-by-the-Hour. The benefits are on both sides; both parties can focus on what they are best at and what is their core business, reducing costs and increasing efficiency. Both parties are interested in long-term cooperation, not a one-off transaction. In light of global problems with access to service engineers, including maintenance staff, the shift of responsibility for the operation of devices from the user to the manufacturer is a natural direction of change.”
There are a few hypotheses revolving around the use of AR service glasses. SECO/LENS augmented reality is currently being explored. This would help in providing remote field service support to the heat treater.
Ipsen’s Goldsteinas has also noted several benefits. He explains the application working by connecting a customer or field service engineer who is at the site with an expert from Ipsen or another service provider. This remote assistance wherein an informant is able to see a problem and give first-hand direction is a common example used to describe the benefits of AR. This application could, for example, decrease the down-time if a furnace were to unexpectedly fail.
Additionally, Goldsteinas envisions training sessions that are conducted in mixed reality. Using virtual reality with an oculus — a type of goggle that digitally enhance or recreate a digitally interactive, environment — companies could reduce training time by recreating experiences, like meetings or practical training sessions, that could be collaborative or solitary. Mixed reality devices like the HoloLens may also be integrated for similar purposes. (Watch video to the right to see examples of Microsoft’s HoloLens and other enhanced reality examples.)
The future could also involve virtual collaboration in the form of an augmented reality meeting room to allow employees from across different Ipsen facilities to discuss and interact with the same content in real-time
3. Efficient Cloud Capabilities
Peter Sherwin personally foresees that attention to the Cloud’s abilities and security will be leveraged in new ways: “An example of this is looking at some of the cost-effective modern-day instrument SCADA [supervisory control and data acquisition] offerings that can provide an on-premise hub for certain applications while managing security policies for linking to cloud based IoT offers.”
4. Increased Systemwide Application
Specifically looking at IoT technologies, Sherwin shared, “I think an expanded view of IoT that encompasses automation across the enterprise (termed as Intelligent Automation or Hyperautomation) is more useful if you really want to achieve significant returns on investment [of IoT technologies]. IoT solutions can improve speed and reduce costs across sales, operations, maintenance, quality, service and administration.”
Advice: To Use or Not To Use
Dan Herring The Heat Treat Doctor®
Dan Herring, The Heat Treat Doctor®, has written about Industry 4.0 and how thinking about seven considerations in any continuation of or change to one’s heat treating process is essential. Ask yourself:
Do I understand what I want to accomplish metallurgically?
Can I predict the outcome of the heat treatment operation?
Can I build repeatability into the process?
Am I using state of the art heat treating equipment?
Am I aware of changes to manufacturing operations?
Am I compromising on quality?
Do I know the costs?
At the end of the day, noted The Heat Treat Doctor®, heat treaters need to know that what they are doing is being done the right way, the first time with the best procedures and processes for their particular operation.
Reflections on The Heat Treat Doctor®
Peter Sherwin of Eurotherm commented on the seven-part advice of The Heat Treat Doctor®, noting, “I think it is very appropriate to look at the value of IoT through the seven considerations that [he] outlines. Building these solutions requires heat treat know-how and an understanding of the data to be captured in order to provide valuable solutions. Value is unlocked in the following categories:
“Right first-time quality improvements. A good heat treater will have quality costs <1% of turnover. The MTI suggests that the cost of quality (all activities) can hit $750k for a decent-size heat treat operation. The knock-on [effects] of poor quality impacts customer satisfaction through delayed deliveries and costs in rework/rejects.”
“Maintenance. These costs can fluctuate – but lets assume a well run plant with fairly modern equipment has costs around 5% of turnover. Significant purchase/cost savings can be made via remote support as well as an understanding of remaining useful life of key components (and avoiding panic purchases).”
“Energy. Again this can fluctuate, but let’s say 10% of turnover. Modern efficient solutions (gas or electric) can significantly reduce the cost of energy and this can be further optimized via IoT solutions.”
“Labor Costs. Say an average of 20% of turnover. Some of the modern XR offers (Extended reality – covers AR, MR, VR etc.) can definitely speed up training, help retention of knowledge, and reduce the time and costs in troubleshooting as well as aiding remote support.”
“It won’t be too long before IoT offers enhanced decision support to heat treaters to aid making profitable decisions,” Sherwin concludes.
Concluding Thoughts
Peter Sherwin Global Business Development Heat Treatment Executive Eurotherm
Whether we like it or not, Industry 4.0 related digital integration is becoming essential rather than simply a better option. Again, the recently published AMS2750F revision highlights this shift for heat treaters.
[blockquote author=”Peter Sherwin, global business development heat treatment of Eurotherm” style=”1″]I think it is important that we use IoT where it can truly bring value and don’t view it as a silver-bullet for everything.[/blockquote]
That does not mean you need to scramble to jump on the bandwagon, but strategically assess your position, your operations, and your options to identify what option is best. Look to other examples in the industry and heat treating tech insiders to inform these new, powerful realities.
Read/Watch More:
Pascal Bornet, Ian Barkin, Jochen Wirtz, Intelligent Automation. Suggested by Peter Sherwin at Eurotherm.
Lindsay Glider, “Rockwell Automation’s 4-Step Guide to Starting Your Digital Transformation Journey,” com (13 October 2020). https://tinyurl.com/yynfoufs.
Are you prepared to adopt Internet of Things (IoT) technologies in your heat treat facility? Do you care to try? In this best of the web article, Aymeric Goldensteinas, production development manager at Ipsen, breaks down how a vacuum furnace can be designed to address the concerns of the modern captive heat treater. As you read this article, learn how to use predictive maintenance, what is Big Data, and how IoT can help you.
An Excerpt
[blockquote author="Aymeric Goldsteinas, Product Development Manager, Ipsen" style="1"]What if your furnace could... Tell you that it isn't operating correctly... Tell you when a vacuum pump rebuild is going to be necessary... Tell you that you are at risk of experiencing discoloration in the next cycle... Tell you that you will not pass the leak back test in three weeks?[/blockquote]
One of the great benefits of a community of heat treaters is the opportunity to challenge old habits and look at new ways of doing things. Heat TreatToday’s101 Heat TreatTipsis another opportunity to learn the tips, tricks, and hacks shared by some of the industry’s foremost experts.
Today’s selection includes tips from Nutec Bickley on how to meet temperature uniformity requirements, and PhoenixTM on how to use “dash cam” tech in your furnace and address the technical challenges in thru-process temperature monitoring.
Heat TreatTip #6
A Products Eye View in the CAB Furnace Using Optical Profiling
PhoenixTM Optic System designed to perform optical profiling in a CAB furnace. A high resolution 4K video camera is protected by an innovative thermal barrier during its journey through the furnace.
Ever wished you could see what truly happens to your product as it travels through your conveyorized CAB furnace? Well now you can! Thru-process Optical profiling is similar to temperature profiling but instead of measuring the temperature of the product the system records a high-resolution video of the products journey through the furnace. It’s like running your car “Dash Cam” but through the furnace at over 1000°F. The resulting video “Optical Furnace Profile” shows process engineers so much more about how their process is operating without any need to stop, cool and dismantle the furnace. This allows safe routine furnace inspection without any of the problems of costly lost production and days of furnace down time. From the video evidence, the root cause of process problems, possibly already highlighted by running the temperature profile system, can be identified accurately and efficiently. Furnace structural damage or faulty furniture such as recirculating fans, control thermocouples or heater elements can be detected. Buildup of unwanted flux within the furnace can be monitored allowing accurate service and clean down schedules to be planned preventing future unplanned costly line stoppages. Damage or distortion of the conveyor belt compromising the safe smooth transfer of product through the furnace can be isolated with accuracy helping reduce corrective action turnaround times.
(PhoenixTM)
Heat TreatTip #7
3 Tips to Meet Temperature Uniformity Surveys
Adjust the burners with some excess air to improve convection.
Make sure that the low fire adjustment is as small as possible. Since low fire will provide very little energy, it will make the furnace pulse more frequently and this will improve heat transfer by convection and radiation.
Increase internal pressure. This will “push” heat to dead zones allowing you to increase your coldest thermocouples (typically near the floor and in the corners of the furnace).
(Nutec Bickley)
Heat TreatTip #12
Temperature Monitoring When the Pressure is On!
PhoenixTM Thermal Barrier used for Low Pressure Carburizing furnace monitoring. Shown fitted with a unique high-performance gas quench deflector.
Increasing in popularity in the carburizing market is the use of batch or semi-continuous batch low pressure carburizing furnaces. Following the diffusion, the product is transferred to a high-pressure gas quench chamber where the product is rapidly gas cooled using typically N2 or Helium at up to 20 bar pressure.
In such processes, the technical challenge for thru-process temperature monitoring is twofold. The thermal barrier must be capable of protecting against not only heat during the carburizing but very rapid pressure and temperature changes inflicted by the gas quench. From a data collection perspective to efficiently perform temperature uniformity surveys at different temperature levels in the furnace it is important that temperature readings can be reviewed live from the process but without need for trailing thermocouples.
During the gas quench, the barrier needs to be protected from Nitrogen N2(g) or Helium He(g) gas pressures up to 20 bar. Such pressures on the flat top of the barrier would create excessive stress to the metal work and internal insulation / logger. To protect the barrier therefore a separate gas quench deflector is used. The tapered top plate deflects the gas away from the barrier. The unique Phoenix design means the plate is supported on either four or six support legs. As it is not in contact with the barrier no force is applied directly to the barrier and the force is shared between the support legs. The quench shield in addition to protecting against pressure, also acts as an additional reflective IR shield reducing the rate if IR absorption by the barrier in the vacuum heating chamber.
AMS2750F, a rewrite of the specification that covers pyrometric requirements for equipment used for the thermal processing of metallic materials, was released at the end of June. For this Technical Tuesday feature, Heat Treat Today asked a few experts in the aerospace industry to share their insights of this much anticipated revision that helps to better clarify issues with the previous revision. Specifically, Heat Treat Today wanted to know what they perceived to be the top 2-3 most important changes in revision F; what companies should do to prepare for these changes; and additional thoughts about the revision as it relates to aerospace heat treating.
Andrew Bassett was on the subteam for AMS2750F as well as the previous revision AMS2750E and has been a member of AMEC and SAE Committee B since 2006. He shares some “inside baseball” background about this four year process, “The AMS2750F subteam utilized the Nadcap Pyrometry Reference Guide, the Nadcap Heat Treat Audit Advisories that pertained to Pyrometry, and the collective experience from the sub-team which dealt with the previous revision issues and problems. The AMS2750F sub-team had a broad range of backgrounds, with representatives from Boeing, Safran, Arconic, GeoCorp Inc, Nadcap-PRI, and Aerospace Testing & Pyrometry.”
What do you believe to be important changes in revision F?
Jason Schulze, Director of Technical Services; Special Process – Metallurgy, Conrad Kacsik Instrument Systems, Inc.
Jason Schulze comments on offsets saying, “Offsets have often been a confusing subject throughout the years. How they are applied, removed and documented has caused confusion and has been a source of Nadcap findings. With the changes to the offsets section of AMS2750 in the new revision, these issues will be greatly reduced. Offsets have now been split into two categories; correction offsets and modification offsets. It will be important for suppliers to understand and implement the new requirements as well as use the same verbiage as this will hopefully alleviate further confusion.”
Andrew Bassett, President, Aerospace Testing and Pyrometry
Andrew agrees this is an important change regarding the offsets and further clarifies, “A “Modification Offset” is when an instrument is purposely, either through electronic means or manual means, shifts the accuracy away from the nominal temperature. This is typically done to “center a temperature uniformity” that may be skewed in one direction or another. The modification offset, when used properly, will shift the temperature uniformity more towards the set point of the thermal processing equipment. A “Correction Offset” is used to bring the instrument back to the nominal temperature. As always, a well defined procedure will be required on how the “Correction Offset” and “Modification Offset” will be introduced into your system.”
“One of the biggest changes that caused a lot of controversy was the restricted re-use of expendable test thermocouples,” Andrew notes. “The AMS2750F subteam provided studies and data that showed that there was considerable drift of certain types of base metals thermocouples, especially when it came to Type “K” thermocouples. The previous revision of AMS-2750 already had restrictions on these types, but after providing data of the drift of these thermocouples, the team felt further restrictions were required for Expendable Base Metal SAT & TUS Sensors. Section 3.1.7.3 describes the limitations of these type thermocouples. Types “M”, “T”, “K” & “E” shall be limited to 3 months or five uses, whichever occurs first between 500F and 1200F (260C and 650C) and is limited to single use above 1200F (650C). Types “J” and “N” shall be limited to 3 months or ten uses, whichever occurs first between 500F and 1200F (260C and 650C) and is limited to single use above 1200F (650C).”
Peter Sherwin, Global Business Development Manager for Heat Treat, Eurotherm by Schneider Electric
Peter Sherwin comments on instrumentation, “From an instrument perspective our no.1 focus is the instrument accuracy specification. This has not changed for Field Test or Control and Recording Instruments (now in Table 7), however the impact of the decimal place for digital recorders could cause some issues for less precise instrumentation. In 3.2.3.1 All control, recording and overtemp instruments shall be digital 2 years after release of AMS2750F – this was not a surprise, and today’s overall cost (paper, pens, storage etc.) of paper chart recorders cannot match their digital counterparts. Digital time synchronization (3.2.3.19) is also sensible to ensure you have an accurate time record across a number of Furnaces/Ovens and charts – we are used to this for other regulations (e.g. FDA 21 CFR Part 11) and offer a SNTP/Time Synchronization feature in our Recorders.”
Jim Oakes, President, Super Systems, Inc.
Jim Oakes shared his pleasure with section 3.2.3.12, “I was happy to see the document address integrated recording/controlling data. It states in section 3.2.3.12when the control and recording system is integrated such that the digitally displayed control value and digitally recorded value are generated from the same measurement circuit and cannot be different, it is only necessary to document a single displayed/recorded value for the control reading. This is happening through direct communications, so what you see on the controller is what you are recording electronically. This saves a step and eliminates the need for additional documentation.”
Doug Shuler, Lead Auditor, Owner, Pyro Consulting LLC
Doug Shuler cites the auditor advising piece, “The top of the list has to be the overall progress we made by incorporating auditor advisories and pyrometry reference guide FQS into the body of the specification so users don’t have to ask themselves “What did I miss.”
How should companies prepare for these changes?
Jason Schulze’s advice to companies focuses on training, “Companies should receive concise training regarding the revisions within AMS2750F, including administrative and technical. As with any training, continuous courses may be necessary to ensure comprehension. I recommend performing a characteristic accountability for each and every requirement stated within AMS2750F.”
Peter Sherwin encourages companies to ready instrumentation for the standards, “Recent feedback from the MTI indicated that 3rd party audits to the new standard would probably start next year. However, if you are in the market for a new instrument then it only makes sense to ensure this meets the requirements of the updated standard.”
Doug Shuler sees the benefit of analysis, “Users should prepare by performing an internal or perhaps an external gap analysis to establish where their pyrometry system is today, and what has to be changed going forward. Users don’t have to wait until AMS2750F and AC7102/8 Rev A are released and in effect before making changes. The key is that if a user has an audit before the revised Nadcap Checklist AC7102/8 Rev A becomes the law of the land, they will have to declare compliance to AMS2750E or AMS2750F in full and will be held to that revision’s requirements. Once AC7102/8 Rev A takes effect (best guess after January 1, 2021) all audits will be done to AMS2750F.”
Andrew Bassett recommends, “First and foremost, get a copy of AMS2750F and start the review process. Since the document was a complete re-write, there is no change summary or change bars to point the supplier in the direction of what has changed. Spend time creating a matrix of the previous requirements (AMS2750E) and comparing to the new requirements (AMS2750F). I would suggest breaking this matrix down into four main sections: Thermocouples, Calibrations, System Accuracy Testing, and Temperature Uniformity Surveys. This will allow suppliers to work on each section without getting overwhelmed by the entirety of the specification. Currently at the time of writing this, there is no formal implementation requirement for AMS2750F. Typically this will either be dictated by the suppliers’ customers, or in the case of Nadcap, they will issue a “Supplier Advisory” as to when their expectation for implementation will be.”
Final Thoughts
Planning for the future will serve companies well for the long term encourages Doug Shuler, “With a number of significant changes, nearing a complete rewrite, now is a good time to take a look at your internal procedures that may have become fragmented over the years and streamline them to the new revision. Auditing for Nadcap for over 10 years has shown me one thing for sure. Those companies that have a thermocouple procedure, a calibration procedure, a SAT procedure, an alternate SAT procedure, a TUS procedure, and maybe even multiple TUS procedures for different kinds of furnaces (Air, Vacuum, Atmosphere, etc.) usually have a more difficult time with audits because the SAT procedure also addresses thermocouples, but doesn’t address correction factors because that’s in the instrument calibration procedure… See where this is going? Consider writing one pyrometry procedure with sections in it just like the specification. Then, the SAT section can refer to the thermocouple section for test thermocouples and to the instrument section for test instruments, etc. It’s like re-writing AMS2750, but customized for your facility, your equipment, and your practices. In the end, remember that the pyrometry portion of your Nadcap audit follows my P.I.E. acronym. Procedures that Include all requirements and Evidence to show compliance.”
Paying close attention to the right data solution will alleviate potential headaches when dealing with both the new AMS2750F revision and the CQI9 (V.4 update) says Peter Sherwin, “Many commercial heat treaters will also have to cope with the update to CQI9 Version 4 at the same time! According to the MTI, your ‘end’ customers may request you perform your self-audit to the new standard from this point forward. There is a bit more time allocated to move to digital (3 years), but my advice would be to take advantage of digital solutions sooner rather than later. The right data solution should save you money over time compared to the paper alternative.”
Finally, amidst all the new changes AMS 2750F has offered, Jim Oakes assures, “…the pyrometric requirements that most of us are used to will still be very familiar as this document becomes the new standard.”
Is new technology always an advantage? Do companies need to update everything or a few things? The rapid pace of technology upgrades is dizzying, and many heat treaters can find themselves unsure of whether to embrace it or refuse it.
In thisHeat Treat Today Original Content feature, Gerry McWeeney of Heat Treatment Solutions gives his take on the pros and cons of remote monitoring in heat treatment.
Special thanks to Gerry McWeeney, heat treatment consultant and president of Heat Treatment Solutions, for permission to run this article.
Technology plays a major role today in most industries, and heat treatment is no different. Having been around emerging technology a lot in the last 20 years or so and reviewing recently other types available in the heat treatment marketplace, it is a subject near and dear to me and I was happy to be sought out by friends in the industry to give my opinion on the Pros & Cons.
THE PROS:
SAFETY – This cannot be reiterated enough. By reducing numbers of labor in operating units, remote capabilities reduce the risk for end-user and vendors.
COST REDUCTION – Reduced labor provides a better commercial proposition to end-users on the manpower to equipment discounted rate scenario.
REMOTE START and STOP
Clients can benefit from early switch on to assist getting weld preheat to temperature. While not ideal for every situation, e.g. inside refineries where conditions can change and the need for the buddy system negates commercial benefit, but, in certain situations can assist welder productivity, which helps cost and schedule.
This reduces the risk in emergency situations. The equipment can be remotely isolated without putting people into the units to do this task.
THE CONS:
REDUCED LABOR - At the site, this can have commercial benefits to the customer. It can also have an adverse effect when scope creep or changes to the schedule occur and there are insufficient resources.
LIMITED FIELD EXPERIENCE - Having control and monitoring operators with limited field experience is a risk as they, at times, can be unable to assist adequately when heat treatment or site conditions change.
RULES & REGS - Differing employment rules and regulations across borders and states can have an adverse effect on project harmony between operators and field personnel.
TOO BUSY – Some operators can be charged with monitoring many heat treatments across various different recording devices and projects, some more complex than others. This can cause delays in communications to field when operators have too much on their hands and conditions change. This can be especially true during TAR / OUTAGE season.
The above lists are not complete--there are other softer pros and cons depending on each company’s technology.
Technology alone will not guarantee the heat treatment, that can only be done by correct set up of thermocouples and heating elements in accordance with code requirements and/or engineered drawings that meet code criteria. Technology is here to stay, and advancements in it, when implemented properly, will help vendors and users alike.
“My preference is for control and monitoring at site using remote capabilities with access to view by the client and heat treatment personnel at site”
A century-old producer of die forgings recently needed to improve the process controls on its heat treating furnaces.
With process controls well over 10 years old, Clifford-Jacobs turned to Conrad Kacsik to improve its temperature process control system. The company, which serves a number of industries, including energy, aerospace, construction, mining, forestry, and rail, was eager to improve its temperature process control system, particularly because the incumbent system was producing inconsistent work.
The Challenge
Bud Kinney, Vice President of Innovation and Technology at IMT Corporation
Clifford-Jacobs was not getting consistent, repeatable results from its furnaces. The company also wanted more efficient and automated processes with data acquisition and electronic operating capability.
“We looked at a number of controls companies throughout the Midwest and interviewed them to learn about their experience with system controls and data acquisition,” said Bud Kinney, Vice President of Innovation and Technology at IMT Corporation, the parent of Clifford-Jacobs. “We knew we wanted an integrated system so we started looking at companies that did that as a matter of course. Most companies are limited to traditional controls, but Conrad Kacsik has a lot of experience doing the exact type of job we needed.”
Increasing Demands
Clifford-Jacobs makes forged parts for a variety of clients. Although forging does not generally require as much precision as other types of processes, customers are increasingly demanding, said Kinney.
“We believe that sooner rather than later things like Nadcap will come into forging, and our customers are very interested in us being able to demonstrate that our processes are always in control, even forge heating,” Kinney said. “This project helps ensure that we meet those needs. We couldn’t track things like set-point input values before. That’s another element we wanted to manage.”
Conrad Kacsik built a full process temperature control system that includes SCADA software from SpecView. They were able to retrofit the system on Clifford-Jacobs’ existing 16 furnaces, saving the company considerable expense and time. The temperature process control system uses Watlow F4T controllers paired with SpecView SCADA software, which allows for programming jobs/recipes, remote operation, secure (password protected) operation of furnaces and accurate automatic temperature recording. Conrad Kacsik also added alert lights that allow the operators to quickly see the status of each furnace from the shop floor.
H2: Benefits of Temperature Control System Integration
Clifford-Jacobs has noted several beneficial results from the new temperature control system. These include:
Increased accuracy. The new system runs each recipe exactly and records the results. The company can also control which employees can adjust temperature settings, preventing operators from rushing jobs with a higher temperature or inadvertently setting the furnace incorrectly.
Higher efficiency. With preprogramming, each furnace is always at the exact temperature it needs to be for the given task. An automatic preheat setting also safely prepares the furnace for the workday—eliminating downtime or the need to send an employee in early to start the furnaces.
More speed. Clifford-Jacobs can pre-program any recipe it needs, allowing for highly accurate and fast running of complex processes.
More convenience. Clifford-Jacobs can operate their furnaces from anywhere with an internet connection, or via an iPad used by an approved employee.
Precision for the future. The new system can be part of a Nadcap-approved process should the need arise. The SpecView software and advanced controllers automatically record each job and retain all data for verification.
The Results
“We used to have to use all kinds of resources to provide oversight on temperature control,” said Kinney. “This has given us a heating strategy. We write the recipes we want and just select from those. In addition to that, we know exactly what every furnace is doing at all times.”
The company is also pleased with the increased efficiency. They only heat product when they are ready to run production, and the furnace only uses the exact energy needed for each recipe. They are also saving on staffing, as they used to have to schedule people to ensure the furnace was at the right temperature.
“With this system, we can develop recipes for each part we make, which is both convenient and precise. It’s doing exactly what we expected it to do,” said Kinney.
When processing critical components, heat treaters value and demand precision in every step of the process — from the recipe to data collection — for the sake of accurate performance of the furnace, life expectancy of all equipment, as well as satisfactory delivery of a reliable part for the customer.
So what’s the obstacle to achieving those goals? Gunther Braus of dibalog GmbH/dibalog USA Inc. says, “The general problem is the human.” Indeed, the need to remove the variable of human fallibility plays a significant role in the search and development of equipment that could sense, read, and record data separate from any input from the operator. “As long there is a manual record of values there is the potential failure,” adds Braus.
Now, as part of the quest for precision, particularly in the automotive and aerospace industries, many control system requirements are driven by the need to prove process compliance to specified industry standards like CQI-9 and AMS 2750. These standards allow for and frequently require digital data records and digital proof of instrumentation precision.
With this in mind, Heat Treat Today asked six heat treat industry experts a controls-related question. Heat TreatControl Panel will be a periodic feature so if you have a control-related question you’d like addressed, please email it to Editor@HeatTreatToday.com and we’ll put your question to our control panel.
Q: As a heat treat industry control expert, what do you see as some of the best practices when it comes to digital data collection and storage and/or validation of instrumentation precision?
We thank those who responded: Andrew Bassett of Aerospace Testing & Pyrometry, Inc.; Gunther Braus, dibalog GmbH/dibalog USA Inc; Jim Oakes of Super Systems, Inc; Jason Schulze, Conrad Kascik Instrument Systems, Inc.; Peter Sherwin, Eurotherm by Schneider Electric; and Nathan Wright of C3Data.
Calibration and Collection
Jim Oakes (Super Systems Inc.) starts us off with an overview of the equipment review process, the crucial component of instrument calibration, and digital data collection:
“Industry best practices are driven by standards defined by the company and customers they serve. Both the automotive and aerospace industries have a set of standards which are driven through self-assessments and periodic audits. Instrument precision is defined by the equipment’s use and is required to be checked during calibrations. The frequency of these calibration depends on the instrument and what kind of parts and processes it is responsible for.
The equipment used for these processes can be defined as field test instrumentation, controllers, and recording equipment. Calibration is required with a NIST-traceable instrument that has specific accuracy and error requirements. Before- and post-calibration readings are required (commonly identified as “as found” and “as left” recordings). During calibration, a sensitivity check is required on equipment and is recorded as pass/fail. The periodic calibration procedure is carried out not only on test equipment but also on control and recording equipment, to ensure instrument precision.
Digital data collection is a broad term with many approaches in heat treatment. As mentioned, requirements are driven by industry standards such as CQI-9 and AMS 2750. Specifically when it comes to digital data collection, electronic data must be validated for precision; checked; and calibrated periodically as defined by internal procedures or customer standards. Data must be protected from alteration, and have specific accuracy and precision. Best practice tends to be plant wide systems that cover the electronic datalogging that promotes ease of access to current and historical data allowing use for quality, operational, and maintenance personnel. Best practices in many cases are defined by the standards within each company, but the hard requirements are often the AMS 2750 and CQI-9 requirements for digital data storage.”
Industry Guidelines and Requirements
Andrew Bassett (Aerospace Testing & Pyrometry) has provided us with a reminder of the industry guidelines for aerospace manufacturing (via AMS-2750E, paragraph 3.2.7.1 – 3.2.7.1.5)
The system must create electronic records that cannot be altered without detection.
The system software and playback utilities shall provide a means of examining and/or compiling the record data, but shall not provide any means for altering the source data.
The system shall provide the ability to generate accurate and complete copies of records in both human readable and electronic form suitable for inspection, review, and copying.
The system shall be capable of providing evidence the record was reviewed – such as by recording an electronic review, or a method of printing the record for a physical marking indicating review.
The system shall support protection, retention, and retrieval of accurate records throughout the record retention period. Ensure that the hardware and or software shall operate throughout the retention period as specified in paragraph 3.7.
The system shall provide methods (e.g., passwords) to limit system access to only individuals whose authorization is documented.
“One of the biggest issues I see with one of these requirements will be point 5,” says Bassett. “The requirement is to be able to review these records throughout the retention period, which in some instances is indefinite. I always recommend to clients who may be upgrading or purchasing new digital systems that they should consider keeping a spare system in place to be able to satisfy this requirement. Who knows — today we are working on Windows 10, but in 50 years, will our successor be able to go back and review heat treat data when everything is run on Windows 28?”
“This is a topic that yields great discussions,” adds Jason Schulze (Conrad Kascik). He directs us to a challenge he sees from time to time.
Within the Nadcap AC7102/8 checklist, there is this question: “Do recorder printing and chart speeds meet the requirements of AMS 2750E Table 5 or more stringent customer requirements?” This correlates with AMS2750E, page 12, paragraph 3.2.1.1.2 “Process Recorder Print and Chart Speeds shall be in accordance with Table 5”.
“To ensure the proper use of an electronic data acquisition unit used on furnaces and ovens, these requirements must be understood,” continues Schulze. “Because this system is electronic, it should be designated a digital instrument and not an analog instrument. In doing so, this helps determine what requirements apply in Table 5. The only remaining requirement in Table 5 for digital instruments is ‘Print intervals shall be a minimum of 6 times during each time at temperature cycle. Print intervals shall not exceed 15 minutes.’
With this in mind, it is important to realize that, if your time at temperature cycles are short cycles (such as vacuum braze cycles), the sample rate of data collection may need to be adjusted to ensure it is recorded 6 times during the cycle.
As an example, if the shortest cycle processed is 4 minutes at temperature, a sample rate of every 60 seconds would not conform to AMS2750E because, in theory, the maximum amount of recordings would be 4 times during the time at soak. Now, if the sample rate was modified to every 30 seconds, this would allow ~8 recordings during the time at soak, which then would be conforming to AMS2750E.
Within the realm of electronic data acquisition on furnaces/ovens, this seems to be a frequent challenge for suppliers.”
A Critical Variable: Process Temperature
Nathan Wright (C3Data) agrees and zeroes in on process temperature as a critical variable to be measured:
“No matter the heat-treating process being carried out, complying with AMS-2750 and/or CQI-9 requires that the heat treater measure, record, and control several different variables. One of the more common variables that must be measured, recorded, and controlled is process temperature.
Measuring process temperatures requires the use of a precise measurement system (Figure-1 below), and the accuracy of said measurement system must be periodically validated to ensure its ongoing compliance.”
“The validation process is carried out through a series of pyrometric tests (Instrument Calibration and SAT), and historically these validation processes are highly error-prone.
In order to help ensure process instrumentation, process temperatures, and any other variable that impacts quality is properly validated it is good practice to begin automating compliance processes whenever and wherever possible. C3 Data helps automate all furnace compliance processes using software.”
A “Standard” Mindset
Gunther Braus (dibalog) chimes back in with some pertinent wisdom: “It is not sufficient only to record, you must live the standards like CQI-9, AMS, Nadcap or even your own standard you have set up, so you must survey the data. However, in the old times, there was a phrase: the one who measures, measures crap. In the end, it is all about surveillance of the captured data.
Where you store the data is a question of philosophy: personally, I prefer local storage in-house. Yes, we all talk about IOT, etc., and I do not want to start a discussion about security; it is more about accessing the data. No internet, no data. So simple. We are overly dependent upon cloud usage on the internet.
The automation of the instrumentation precision is so much effort in terms of automated communication between testing device and controller, from my point of view we are not there yet.”
A Look at the Standards In and Outside the Industry
The aim is to record the true process temperature seen by the components being treated. However, there are many practical factors that can alter the accuracy of the reading. From the position of the thermocouple (TC), the TC accuracy (over time), suitability of the lead or extension wire, issues with CJC errors and instrument accuracy as well as electrical noise impacting the stability of the reading.
The standards do a good job to help by prescribing the location of TC, accuracies required for both TC and instrument, and frequent checks over time through TUS and SAT checks but note the specification requirements are maximum “errors”. And if you truly want to reach world-class levels of process control and reap the inherent benefits of better productivity and quality, you should aim to be well inside those tolerances allowed.
With 30yrs+ of data required to be stored (in certain cases, particularly aerospace), there should be some thought as to how and what form this should be stored in. There are many more options of storage when the data is in digital format.
Paper is very costly to store and protect.
The virgin data file should be secure and tamper-resistant and identical copies made for backup purposes held offsite.
The use of FTP is becoming more common to move files automatically from the instrument to a local server (with its own backup procedures to ensure redundant records in case of disaster).
Regular checks should be made to examine the availability and integrity of these electronic records.
Control and Data Instrument suppliers should ideally have many years of supplying instrument digital records with systems that can access even the earliest of data record formats.
We also look outside of the heat treat standards for truly best practices. The FDA regulation 21CFRPart11 and associated GAMP Good Automated Manufacturing Practice have been extended with the new document “Data Integrity and Compliance with Drug cGMP, Questions and Answers, Guidance for Industry”. These updates leverage A.L.C.O.A to describe the key principles around electronic records (see below). This industry is also leading the requirement for sFTP a more secure format of the FTP protocol.
Heat TreatToday will run this column regularly featuring questions posed to and answered by industry experts about controls. If you have a question about controls and/or data as it pertains to heat treating, please submit it to doug@heattreattoday.com or editor@heattreattoday.com.
Welcome to another episode of Heat Treat Radio, a periodic podcast where Heat Treat Radio host, Doug Glenn, discusses cutting-edge topics with industry-leading personalities. Below, you can either listen to the podcast by clicking on the audio play button, or you can read an edited version of the transcript. To see a complete list of other Heat Treat Radio episodes, click here.
Audio: Jim Oakes
In this conversation, Heat Treat Radio host, Doug Glenn, speaks with Jim Oakes from Super Systems, Inc., based in Cincinnati, Ohio. SSI develops and manufactures products for the thermal processing industry, including probes, analyzers, flow meters, controllers, software solutions, and engineered systems. Jim Oakes of Super Systems corrals the data about data and makes sense of its use in the heat treating world, covering topics that include the evolution of data collection, sensor technology, data collection for preventative maintenance, operational benefits of data collection, Super Systems data capture explained, the Cloud and security.
Click the play button below to listen.
Transcript: Jim Oakes
The following transcript has been edited for your reading enjoyment.
On this episode of Heat TreatRadio, we’re discussing data. If there is one thing that is significantly changed in the Heat Treat world in the last decade, it’s the quantity and quality of data. What the heck do you do with all the data? How do you collect it? How do you decide which data sets the capture and after you capture them, how can you learn anything from them? Data, data everywhere, and not a drop to drink!
Welcome to Heat Treat radio. I am your host and publisher of Heat TreatToday, Doug Glenn. Today, we’re going to talk to one of the industries leading authorities on data, Jim Oakes from Super Systems Inc. But before we do, why don’t you take a little cyber trip over to heattreattoday.com and see all the data we have there? We’ve got aerospace heat treat data, we’ve got automotive heat treat data, we’ve got medical heat treat data and energy heat treat data as well as general manufacturing heat treat data. In fact, we’re adding at least one new piece of heat treating data every day. On Tuesday, we publish technical content. We call it ‘Technical Tuesday. If you’re a manufacturer within in-house heat treat, we’re pretty sure you’re going to find heattreattoday.com really helpful.
Before we get started, here is a word about this episode’s sponsor: Today’s Heat TreatRadiois brought to you by Dry Coolers, designers and builders of industrial cooling systems and the professional engineering services surrounding those systems. As a leader in the heat treat industry for decades, they’re located in Oxford, Michigan and supply cooling systems for the aerospace, automotive, medical and energy industries, plus many others. If you have any industrial cooling needs, call Dry Coolers. You can find them on the web at www.drycoolers.com or by phone at 800-525-8173.
Doug Glenn (DG): Let’s get started on today’s topic — data. Our guest is Jim Oakes from Super Systems Inc. Hi, Jim. Take a minute and introduce yourself to our listeners.
Jim Oakes (JO): Hi, Doug, this is Jim Oakes with Super Systems. We’re a technology provider for the heat treating industry. We focus on sensors, controls, and software for the thermal processing and heat treating industry, and we’ve been doing that for over 20 years now.
DG: Jim, how many years have you been in the heat treat industry?
JO: 15 years.
DG: Over the past 15 years, what impresses you about the way we are using data now as opposed to the way we used it back then?
JO: Well, a couple things, actually. My introduction to the industry was actually longer ago than 15 years. I started in an internship, and oddly enough, at that internship — it was for a technology provider in the heat treating industry — I was involved in doing data capture from a PLC at a Timken plant in Gaffney, South Carolina, and that was 25 years ago. Data acquisition has been happening not just in the heat treating industry, but in manufacturing for a very long time. What’s really been changing though, if you look at the last 10 to 20 years, is that the technology is lending itself, because of cost, both from a storage standpoint and processing standpoint, to really being accessible everywhere. You have more information that is coming out of microprocessor controls or PLCs or programmable logic controllers throughout the shop floor. Whether it be a piece of thermal processing equipment or a cooler or anything that is on the shop floor, we have tons of information that is becoming available. Before you might have been worried about how you would store all that information, but that is a thing of the past. The amount of information, and actually making sense of all of it, is where the challenge lies today, certainly not collecting it.
The Evolution of Data Collection
DG: Ten years ago, are you seeing us collecting anything now that we didn’t collect then? Are we collecting more stuff than we were collecting back then, and if so, what are we collecting now that we weren’t collecting before?
JO: That’s a great question, Doug, because back then a lot of the data was very specific and focused on process-related information. Now, there is additional data that is being collected that can be used for some predictive modeling, if you will. It’s not just proof of process that meets the industry requirements. Your customers were expecting that if you used a heat treatment process, then you had to really prove you performed that. Well, that’s a thing of the past. Of course, any data acquisition system that you have today, or anything data-related is going to provide you with that. But now there is more data, so on any day, in any heat treat facility, captive or commercial, I’d say there are 750,000 to well over a million data points that are being collected. Honestly, most people don’t even know that they’re collecting all that information. Their laser focus is on that one specific requirement. All that information that you can have is coming from these microprocessors or PLCs, so the amount of information today versus what you were gathering way back when is really one of the biggest differences.
DG: What are some of the technologies that have driven that change so that now we can collect more?
JO: A couple things. Standardized protocols have been around for capturing data, so you have to have a mechanism to get the data from all of these different pieces of equipment. That’s one piece. It’s existed for a long time. But if you think about it, if you take the shop floor today versus 10 years ago versus 20 years ago, there is a PC everywhere now. You have a networking infrastructure that exists that maybe wasn’t there 20 years ago. Maybe you had a limited number of people that would be able to absorb that information and utilize it. Today, everyone is using a computer. Everybody is using a hand-held device. Now, all of a sudden, that information is readily available to lots of people, and that’s where the difference is. Not only do you have the networking infrastructure on the manufacturing on the shop floor, but you also have the technology that is available to everybody. Computers are everywhere.
Sensor Technology
DG: One of the contentions I have is that the reason we’re able to gather so much more data now is that we’ve had advances in sensor technology. Maybe you can address this a bit. I think there are things we are capturing now that we weren’t even able to capture before because of advances in sensors, whether it be IR sensors, or whatever.
JO: Yes, you’re right, Doug. If you look at the amount of information that is readily available, it is because of the technology that is available to capture it. There is all this sensor technology, whether it’s a limit switch identifying a basket or a tray moving to a specific location, or an infrared device that is used maybe for just measuring temperature on the outside of a furnace shell or an infrared analyzer used for analyzing the gas inside the chamber where the parts are being heat treated. Now you have the ability to take that additional information and use it for a decision making process.
And now you have all this data. Nobody is concerned about the amount of information you’re storing. Nobody ever says, “Well, we’re not going to have that much space.” The problem is people and time in actually evaluating all of the data. No doubt, using a sensor to monitor vibration of a pump or motor, or looking at the current usage, or looking at gas usage — the list goes on of the amount of information you can gather and this is because the cost has gone down. Each of those specific devices are now lower in cost and reasonably achievable from a data capture standpoint.
DG: We might describe it as to say something like: In the past, we used to put all the sensors inside the furnace, as you mentioned, to validate the process and things of that sort. It seems now that, because of cost of sensors and things of that sort, the fact that you can gather all this data and actually do something with it now, that we’re getting sensors on the outside of the equipment to make sure not that just the process is validated, but that the equipment is also validated, if you will, so that we can see troubles coming and that type of thing. Do you agree?
JO: Yes, there is no doubt if you look at some of the benefits of what we see in the heat treating industry today. Of course, operational efficiencies are important. Now you’re taking the data that you’re gathering, again it’s not going to just prove that you’re running the parts properly, but you’re able to make better decisions from an operational standpoint. You can look for better load planning, you can look for reducing time between loads or gap time between loads and identify what’s causing those. The other thing is using this information for preventive maintenance. The equipment manufacturers are doing a great job with providing preventive maintenance programs and it is because of the sensors and the data acquisition systems that you are able to even just locally to that piece of equipment or gather from a plant-wide standpoint. There is no doubt, that some of the biggest benefits are from doing the data capture and then having this different sensor technology that allows for the preventive maintenance programs that can be put into place.
DG: Isn’t that, in fact, where huge benefits can be gained, in the area of preventative maintenance?
Preventative Maintenance
JO: Unplanned downtime is a huge cost component in heat treating. Anything you can do to manage the up-time of your equipment is beneficial. Of course, planned downtime gives you an opportunity to work with customers, work with the product that is flowing through your facility as well as managing the incoming parts that you might need for that equipment. So it’s a huge benefit. You can still do preventive maintenance programs that are in place; it doesn’t have to be with new equipment. You just have to be smart about the things that are important to that equipment and then utilize that data. I always say that data acquisition is very underutilized when it comes to maintenance. The maintenance department is usually one of the busiest groups within the thermal processing industry. A lot of domain knowledge goes into the equipment, but they have a lot of this information that is readily accessible to them, so if they could look at this information and anticipate that fan is going to fail, that motor is going to fail, that there is a short on your electrical elements, or whatever that might be, you’re going to be able to plan for the downtime. That’s going to help from an operational standpoint as well as reduce the amount of time that that furnace might be out of commission.
DG: And when you’re not planning ahead, when you’re responding to fires rather than preventing fires, so to speak, it is usually the maintenance guys who catch the brunt of it.
JO: Yes, that poor guy walks into work every day dreading work because he’s got a crisis on his hands every single time. If you can prevent that crisis, so he can plan to do something, it’s a totally different work environment.
Let’s take a quick break here and remind you that additional support for today’s Heat TreatRadio episode is being provided by Dry Coolers. If there is one thing we know about thermal processes, it’s that things get hot, and to remove that heat from critical areas, you need a system that is reliable, and if necessary, designed for your specific needs. The fact is, Dry Coolers has been custom designing and providing standardized units for decades, and they have the staff and experience to take care of any of your industrial cooling needs. If you’re a manufacturer with in-house heat treating and you need an industrial strength cooling system, make you first, and only call to Dry Coolers. You can look them up on the web at www.drycoolers.com.
Now let’s get back to our interview with Jim Oakes of Super Systems.
DG: Where are you seeing data being used well?
Operational Benefits of Data Collection
JO: The people that are taking advantage of the information are of course meeting the industry requirements. They are staying on top of things like CQI-9 or NadCap requirements from a data collection and meeting the customer requests. That is the foundation. I always say that in a lot of cases, that is a big driver for electronic data. But the people that are really taking advantage of that are using that information for operational benefits. Operational can be both from a maintenance standpoint as well as just improving your overall operations. You’re looking at, “Why do I have downtime of two hours between loads on this particular piece of equipment?” So now, instead of using somebody to go search the shop for, and walk out and get a paper chart, you now have people that can actually evaluate the downtime between loads. You can look at gap times and identify what the issue is. Is it because I don’t have enough fixtures? Is it because I don’t have enough labor? The labor market is tight right now, so you want to use something that is going to provide you with something to maximize efficiency with what you have. Challenges might be your labor or might be your equipment. Are you making the most of your equipment? You can look at that data. You have tons of information. If you can evaluate that, it gives you an opportunity to make better decisions. That is one area.
The other area is, how can you utilize the data and push that out to all your people. Let everybody look at this, but only give them the pieces of information that are important. The maintenance department is going to be interested in maybe the percent output, the current going to the electrical elements, vibration, or water temperature. That information is relevant and if they could isolate that information, they can sit down with their cup of coffee in the morning and they can evaluate this information. Before they have to react to all the firestorms that they have in front of them, maybe they can actually plan for some preventative maintenance activities based off what the data is telling them. The right information to the right person is really critical. The people that are doing this are the ones that are really taking full advantage of the information that they have with a SCADA package.
DG: Is there someone out there that is actually doing it?
JO: Yes, absolutely! There is no doubt about it. People are taking resources, and instead of being reactive and trying to find stuff on the shop floor, they are using the system to identify, answer customer needs and then create those operational efficiencies. People absolutely, no doubt, are taking advantage of that. They are looking at shortening time between loads, notifying users when loads are done so they can get the parts out and then put new parts in. This is happening with mobile devices and/or emails so that the right people are notified at the right times.
DG: Give us the lowdown on what SSI is doing in this area.
The SSI Data Capture
JO: Our foundation provides us the ability to provide information everywhere. This starts with the sensor and taking that sensor data into a controlling equipment, whether course microprocessor control PLC. But you need to make that readily available so that people can make decisions quickly. Proof of process is one thing of course, but so is giving access to information, whether by mobile device or a messaging system. So we’re taking all of the information that we’ve already done in the past and providing that into the technology that people are utilizing today. We see huge opportunities from being able to go through the existing data that’s there, and then look at better ways to capture data based off the technology that is becoming available, whether it’s how we capture usage of gas or usage of electricity or just process-related data to make sure that the right person is getting the right information.
DG: Many of the folks reading this article are manufacturers with their own in-house heat treat plants, and I’m guessing that many of them are wondering what they can do to move in this direction. What should these folks do next?
JO: First step is to do an inventory of the equipment and be realistic about what data you can get out of them, highlight the drivers, meaning what are your business drivers for capturing that information, and then at that point decide if it is just the infrastructure from a data acquisition standpoint or, if you want to get some bigger bang for your buck, maybe you want to make an investment in some equipment that is technology down at each piece of equipment level, to capture that so that you can realize the gains based off of capturing that information.
DG: If a company wants to move in this direction, must they go cloud-based?
The Cloud and Security
JO: No, definitely not. The cloud is a tool that allows basically data and information to be stored externally. The reality is a virtual server in many degrees can potentially be a cloud-based system, but it doesn’t have to be. A large number of the installs we have are storing information locally and then transferring data to the cloud for backup recovery.
DG: Address cloud-based security, if you would.
JO: It is a huge topic from a security standpoint and I would say that most of the companies that use the SCADA packages are on-premise. That is not all of them, but most of them are. This means that if you are on premise, you have a private network where it is not accessible from anywhere unless you create that tunnel into that private network using virtual private network. That’s what you refer to as on-premise. Then you have cloud-based system, which is really just pushing that information up to a server form which provides access into it. Of course, there is a security aspect regarding accessing that information. A strategy has to be put forth that prevents external access to that information. In many cases, if you decide that you’re going to go to a cloud-based system, you’ve already thought through that and you’ve probably already transitioned some other systems to that. Anyone that is going to a cloud-based system has some security requirements to prevent any illegal or unwanted access.
DG: Jim, thanks for your time.
JO: Doug, thank you for having me on Heat Treat Radio. I really appreciate the opportunity. This topic is important to us here at Super Systems. As a technology provider to the industry, we really like to get the word out there about what types of things are coming, whether it’s making data accessible at the hand-held level, or helping make decisions, it is something that is near and dear to our heart and that is because a lot of our customers really find this necessary. I appreciate you spending the time with me and I really look forward to having discussions around this in the future.
That was Jim Oakes of Super Systems Inc. talking about data and how to get the most out of that data. If you’d like to get in touch with Jim, please email me directly at doug@heattreatoday.com and I’ll put you in touch with Jim. Super Systems can be found on the web at supersystems.com.
Suffice it to say, you will be hearing more from Heat Treat Today about data and how to use it more effectively for your business. To see more heat treat technology articles, go to www.heattreattoday.com. We post a new heat treat item, either a technical article or some industry news, every weekday. If you’d like more Heat TreatRadio, simply Google H”eat Treat Radio”. We’re the first thing that pops up. You can also subscribe to Heat TreatRadio on iTunes or SoundCloud.
One last reminder that today’s episode of Heat Treat Radio was underwritten by Dry Coolers. If you have need for any industrial cooling system, give the good people at Dry Coolers a call. They are on the web at www.drycoolers.com.
This and every other episode of Heat Treat Radio is the sole property of Heat Treat Today and may not be reproduced without express written permission and appropriate attribution from Heat TreatToday. Jonathan Lloyd of Butler, PA, produced and mixed this episode. I am your host, Doug Glenn. Thanks for listening.
Doug Glenn, Heat Treat Today publisher and Heat Treat Radio host.
To find other Heat Treat Radio episodes, go to www.heattreattoday.com/radio and look in the list of Heat Treat Radio episodes listed.
Controlling process temperature with accuracy and without extensive operator involvement is a crucial task in the heat treat shop and calls for the use of a temperature controller, which compares the actual temperature to the desired control temperature, also known as the setpoint, and provides an output to a control element. This comparative process relies upon an algorithm, the most commonly used and accepted in the furnace industry being the PID, or Proportional-Integral-Derivative, control.
“This popular controller is used because of its robust performance in a wide range of operating conditions and simplicity of function once understood by the processing operator,” writes Real J. Fradette, a Senior Technical Consultant with Solar Atmospheres, Inc, and the author of “Understanding PID Temperature Control as Applied to Vacuum Furnace Performance” (with William R. Jones, CEO, Solar Atmospheres, Inc, contributing).
The PID algorithm consists of three basic components, Proportional, Integral, and Derivative which are varied to get optimal response. If we were to observe the temperature of the furnace during a heating cycle it would be rare to find the temperature reading to be exactly at set point temperature. The temperature would vary above and below the set point most of the time. What we are concerned about is the rate and amount of variation. This is where PID is applied. ~ Fradette
In this week’s Technical Tuesday, we direct our readers to Fradette’s article at Solar Manufacturing’s website where he and Jones cover the following on PID temperature controllers:
Definitions, e.g., Closed Loop System; Proportional (GAIN); Integral (RESET); and Derivative (RATE)
Actual operation of a PID temperature controller, including understanding PID dimensions and values; and general rules for manually adjusting PID
One of the most important advances in batch integral quench (BIQ) furnace systems has been the development of innovative control systems. Many BIQ manufacturers have developed their own highly sophisticated and cutting-edge control systems.
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