Originally published on GMI blog by GM International| June 26, 2019   In an industrial environment, security specialists need to shield communication networks from surges and transients using electrical insulation or voltage stabilization. Let's see which solution fits best different scenarios. The most widely applied differential digital transmission standards in this area are EIA/TIA-422 and EIA/TIA-485, i.e. RS-422 and RS-485. They offer advantages in terms of robustness, cost-effectiveness and resistance to external interference. However, there's a flip side: industrial environments are usually very complex, as they combine equipment that usually work for long periods, if not always, with outstanding performance, according to the type of production. In addition, data networks often cover long distances, further increasing potential risks. Accordingly, data-circuits may be damaged by malfunctions on the path: electrical noise, lightning strikes, overvoltages which can lead to transients passing through the serial communication system and the connected machinery as well. Again, the number of "nodes" within the network, with different ground potentials, could cause ground currents to flow along the path which offers the lowest resistance, i.e. grounding. However, the results are always the same: serious damages to equipment considered essential for the activity, meaning production shutdowns, delays, rising costs and in the most serious cases also risks for human life.   Most common issues The above mentioned potential risks can be roughly classified into two categories: very high voltages (several kV) with a very short lifespan (thousandth of a second), such as lightnings and sparks, electrostatic charges, switching of large inductive loads and so on; and then, less relevant voltages with a very long lifespan, usually generated by a short-circuit that occurs between the data network and the power supply cables. Interference that could affect the grid can also be divided into two categories: the common ones, measured with respect to the local ground of the circuit, and the differential ones, which can be measured on the basis of two lines, such as the one that carries data and high voltage supply.   How the voltage stabiliser and isolator work Let's see how the voltage stabilizer and the isolator work so as to identify the most suitable application settings. A voltage stabiliser is a device that limits the input voltage by blocking or shorting to ground the voltages exceeding a specific threshold, thus dissipating the surplus energy transmitted, for example, by a thunderbolt. The isolator, instead, is a device intended to isolate the voltage considered dangerous in a single area of the system, so that it does not temporarily or permanently damage the other parts. An isolator converts signals carrying data into light pulses or into an electric field then, once completed, the signals are turned back into data and overcome the obstacle. As a result, data lines and ground lines are separated, so no ground loop accidents can occur. In addition,  thanks to this segregation, the isolator keeps the data line free from interference caused by electric and magnetic fields.   Both technologies are suitable and useful for the industrial sector, although some aspects have to be considered when designing the plant. The voltage stabilizer, for example, may not be enough, and if wrongly chosen and installed, damages may even outweigh the benefits. The same applies to the insulator: very high transients could damage it making it useless. Having considered the pros and cons, it is often worthwhile to combine both solutions by choosing the appropriate location for each of the two devices according to the specific application. The voltage stabiliser, for example, is more effective when used as a primary power line protection, while an isolator effectively protects the signal. Matching the two of them, the best protection level is thus achieved. ... View more

Originally published on  GMI blog   by GM International | October 30, 2019                   The latest edition of the European Guide to application of the Machinery Directive introduced some significant new interpretations. Let’s look at the main ones. The aim of Machinery Safety is to ensure the safety of workers, process facilities and users coming into contact with various types of machinery, and to integrate safety in the design and construction phases, all the way through to correct installation and maintenance. Manufacturers and Employers have to ensure that any machinery on company premises complies with Article 70 of Italian Legislative Decree 81/08 (Consolidated Law on Safety) which applies to machines manufactured since 1996 with CE marking; to machines prior to 1996 which will have to be checked for minimum safety requirements, in accordance with Annex V; and to modified machinery which will require new certification. According to the   Machinery Directive 2006/42/EC   (which came into force throughout Europe on 29 December 2009 and is known as the New Machinery Directive) machinery is defined as “an assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application”. The latest new legislation is edition 2.1 of the   European Guide   to the application of Directive 2006/42/EC, issued in late July 2017 and made public in early 2018. It contains some significant new interpretations. Here are the main ones: 1. Regulations on use of machinery.   When commissioning a machine, national regulations and directives established by various member states shall in no way undermine the provisions of the directive itself. 2. State of the art. It introduces the concept of "State of the art".   At the time of manufacture, the manufacturer is required to equip the machine with the best safety measures, taking into account the current state of the art in technology. 3. Intended use.   The importance of the intended use of a machine is underlined as being essential for the manufacturer as well as for the user and for non-professional personnel, in order to evaluate its safety. 4. Meaning of “equipment”.   A piece of machinery shall be regarded as a machine only as an assembly and with regard to the specific use for which it is intended. 5. Meaning of “partly-completed machine”.   A partly-completed machine is a piece of equipment that cannot perform its specific application independently and is therefore incorporated into an assembly to which the Directive can be applied. 6. Meaning of “assemblies of machinery”.   “Assemblies” means machines or partly-completed machines, assembled and   controlled so as to ensure complete operation of the assembly correlated with safety protections. 7. Change management.   When changes are brought in that introduce new risks, which render current safety measures insufficient, the manufacturer is required to affix new CE marking to it. Another interpretation is provided by the current digital revolution and by national plans based on Industry 4.0. On this basis, institutions and corporations are beginning to take into consideration whether or not to introduce a new European Directive on “intelligent machinery” which would regulate human-machine interaction and the growing importance of cybersecurity, artificial intelligence, IoT, Big Data and other digital technologies which are built into such machinery. Finally, it should be noted that depending on the sector of use, in accordance with the Machinery Directive, other safety standards, directives and approvals may be applied and which GM International includes in its products:   ATEX   and   IECx, EAC EX, Nepsi, TIIS for intrinsic safety, DNV and KR for marine applications, SIL and TÜV for functional safety, UL, FM, CSA for the North American market, as well as other international metrological certifications.   ... View more

Originally published on  GMI blog   by GM International | November 20, 2019       In the Oil & Gas sector, any shutdown of a process facility is a highly undesirable event. Below we set out some best practices and technologies to ensure that countermeasures are effective.   Attention to safety is a key factor in the Oil & Gas sector, where the nature of the processes and tasks involved requires extraordinary precautions to be taken. For sector stakeholders, it is crucial to maximize operational efficiency and safety while reducing risks, protecting the environment and corporate assets, and complying with regulations. Downtimes, breakdowns and shutdowns are one of the main sources of hazards and financial losses at process facilities. However, a few overall general strategies can help to avoid or minimize such events. Let's look at them together briefly. 1. Access to real-time data. Latest-generation IT and HMI/Scada platforms can handle real-time data even in web architectures, distributed via standard connectivity from any access point. This makes it possible to connect the various sections of a process facility or pipeline, transport system, measurement or accounting system, refinery or off-shore platform. 2. Remote control. Revamping, maintenance, process facility management and data collection operations mean optimizing processes via remote control and other monitoring tools, in a Web 4.0 system. The roots of such a vision are firmly entrenched in the promising IIoT (Industrial Internet of Things) technology market. 3. Edge Computing. Edge computing is a cloud-based IT service environment, managing information on the edge of the network, where the data are produced. This enables Edge technology to be used in distributed environments typical of the Oil & Gas sector, at installations and at the sources of data, thus reducing delays and transforming management models. 4. Control, safety and diagnostics systems. In order to maximize efficiency, reliability and safety, extraction systems, oil pipelines and gas process facilities in general are becoming increasingly integrated. This involves using connectivity and control systems in compliance with the strict regulations governing the sector and supported by powerful diagnostic and supervisory tools. 5. Updating or replacing obsolete systems. Failures and downtimes of obsolete systems affect order delivery times and lead to unbudgeted additional costs. It is therefore crucial to check the wear on electronic components in the system by defining availability/repairability/replacement for obsolete components, drawing up revamping plans and installing performance detection sensors. 6. Predictive maintenance. Oil & Gas work is generally carried out in critical environments using complex KPIs. Intelligent use of data and predictive maintenance employing mathematical models to identify faults in advance offers better overviews of the status of process equipment, reducing downtimes and unplanned interventions. 7. Inverters and speed variators. Obsolete, old or damaged electric motors can be highly inefficient, compromising the performance of the system, even leading to shutdowns. Installing inverters, speed variators and specific, high-efficiency soft starts help to improve motor performance and durability. 8. Safe design. Designing process facilities in compliance with the IEC 61511 standard is the correct approach to deal effectively with Oil & Gas-related safety and reliability issues. This makes it essential to draw up a comprehensive risk analysis policy that will include configuring, installing and commissioning of the SIS (Safety Instrumented System), allocating SIFs (Safety Instrumented Function) to protection levels and determining the corresponding SILs (Safety Integrity Levels). 9. Training. The drivers of transformation, even in the crude oil sector, can be found in the technological evolution and in the staff training required, involving sensors, remote control, software and condition monitoring. Training must also preserve and pass on best practices and guidelines arising from the experience handed down by users, builders, maintenance engineers and engineering companies. For example, in the functional safety area, GM International offers courses compliant with the FSE (Functional Safety Engineering) certification scheme adopted by TÜV Rheinland for safety instrumented systems (SIS) according to IEC 61508/61511 standards. 10. Security. The Oil & Gas sector is a particularly attractive target for cyber criminals. There are many different access points that could be used to attack critical infrastructures and many targets where tampering could lead to large-scale disasters. Oil & Gas companies have to carry out massive information gathering and security-by-design operations to prevent and minimize the impact of cyber attacks.   ... View more