Spring Edition

PLCs
SPRING EDITION
Contents
3 — A new future for process control systems
9 — AutomationDirect is your TOP Choice for affordable PLCs
10 — Tips on how to choose industrial controller hardware,

software
18 — PLC module coordinates real-time data in coal

shipping application
25 — Intro to Git-Based Version Control for Industrial

Automation
44 — PLC migration improves uptime for spice supplier
46 — Achieving on-stream control room relocations
2
A new future for process
control systems  Back to TOC
Industrial control systems need to change and future process automation

systems need to deliver on these new expectations.
M any challenges have confronted industrial companies in recent years, rang-

ing from the pandemic and its attendant supply chain issues and rising labour
shortages, as well as geopolitical disputes and the perennial need to cut the effect
that industrial activities have on the environment. The combination of these events
and trends is leading process industry companies to look again at how they operate
and the control systems they use to manage their production.
Since their advent over 40 years ago, distributed control systems (DCSs) have
changed to meet new demands, with one major development being digitalization.
These new “digital DCSs” allow users to maximize productivity, find new collaboration
methods and also keep operators engaged, while keeping the DCS’s core functions at
the centre of operations.
Adapting for the future

DCSs will need to become more flexible as their users’ needs change. This flexibility
and openness to change will allow them to add new functions easily.
Evolving gradually to meet new user needs and taking advantage of new technolog-
ical developments means that the future DCS can avoid the need for a ‘big bang’
change that could be very costly and disruptive. A modular approach allows parts of
the system to be changed without replacing the entire system.
3
A new future for process control systems
The way to achieve this flexibility will be through radically changing the architecture  Back to TOC
of the DCS. This change will see the control system core functions separated from the
less critical features, leading to an extended automation environment that helps bet-
ter collaboration between people, systems and equipment.
One organization helping map out this evolution is NAMUR. It has created the open
architecture (NOA) model which adds a layer to the DCS to allow extra functions –
such as asset and device management, optimization and planning, while avoiding the
disruption involved in making changes or upgrades. This is achieved through building
an open and secure environment that can integrate IT components from the field up
to enterprise level.
An example of this is using edge and Cloud computing technology to help companies
to achieve the benefits of IIoT-enabled sensors. Companies can collect and analyse
huge quantities of data, while sharing it across the organization.
Because this scheme moves non-core functions to a connected-yet-separate digital

environment, users’ systems can more easily adapt as their needs change. New and
more innovative offerings can be adopted more quickly, while placing existing appli-
cations in a virtualized, digitally native environment allows enhanced cybersecurity.
Project execution
As markets develop and customers become more demanding, companies are under
pressure to get new production units online faster. One way of doing this is to mini-
mize the time and resources needed to deploy DCS solutions, which can be done by
separating automation hardware and software engineering at the set-up stage. This
4
 Back to TOC
method of parallel working can cut project delivery times by Courtesy: ABB news release
between 10% and 40%.
Using pre-made and pre-tested automation software modules can also give significant
time savings. By cutting time-consuming tasks, future DCSs will allow companies to
use their engineering teams more effectively.
Modern plants offer a lot of data, but much of it is not actually used. Companies
clearly find it difficult to collect, analyze and use data effectively to optimise their
plant performance.
5
Digital technologies help  Back to TOC

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New business models for DCSs  Back to TOC

Specifying and purchasing hardware based DCS systems can become a lengthy and
costly business. Separating hardware and software in the digital DCS can help avoid
this process. The new digital ecosystem allows changes to be made much more quick-
ly at far lower cost.
New business models, including software-as-a-service (SaaS) and platform-as-a-ser-

vice (PaaS), have cut the time to purchase and install a DCS while self-service free tri-
als and pay-as-you-use schemes allow companies to pick and choose applications and
services. These approaches help DCS users adapt their system easily as needed when
new challenges and demands make themselves felt.
Automation systems also play a role in helping operators deal with labour shortages
and the knowledge gap. People are still needed for the more complex situations, but
the goal is that future autonomous control systems will also be able to handle these.
Using AI is a major route to this increased autonomy. ABB, for example, has devel-
oped its own six-level taxonomy of autonomy, which considers the scope of the au-
tomated task and the role of any people involved. The taxonomy starts at Level 0, no
autonomy, while Level 5 indicates the system is completely autonomous.
AI and machine learning algorithms will also bring benefits to engineers, giving
them the information needed to solve process problems in the field. Mobile access
to data allows them to assess process conditions in real-time, while Augmented
Reality (AR) tools can overlay information on top of a real-world view and provide a
link with experts.
7
 Back to TOC
A bright future
The flexibility of the latest generation of digital technologies, combined with initia-
tives such as NOA, mean that the future is looking bright for the DCS.
Set to become increasingly open in both functionality and usability, DCS solutions will
offer industrial operators more functions and an increasing number of opportunities
as they seek to make their operations more effective and sustainable.
Johan Björklund
Johan Björklund is responsible for portfolio management and sales enablement for
control systems within ABB.
8
AutomationDirect is your TOP Choice for affordable PLCs
 Back to TOC

AutomationDirect is your TOP Choice
for affordable PLCs
AutomationDirect is your top choice for affordable PLCs. Break
out of the inflated Distributor pricing model with upfront
pricing, no expensive service contracts, Free technical support,
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of several award-winning PLCs. With AutomationDirect we
provide the tools to support your many innovations.
9
Tips on how to choose industrial
controller hardware, software  Back to TOC
Choose the right programmable logic controller (PLC) hardware and

software and consider ways to make PLC programming more efficient. Get
advice below, from the PLC hardware and software webcast, archived for a
year after Sept. 29.
I ndustrial controller hardware and software are central to smoothly operating automa-
tion, and “How to choose industrial controller hardware, software,” from Control En-
gineering, part of CFE Media and Technology, previewed below, offers more on those
topics. The Registered Continuing Education Program (RCEP) offers one professional
development hour (PDH) upon successful completion of an exam after this webcast.
This PLC course will look at issues related to programmable logic controller (PLC)
hardware and selection and programming. Most manufacturers or facilities have some
of this software and some of that hardware for industrial control applications. When
there’s an expansion planned, do you stay with existing vendor(s) or consider some-
thing new? What criteria are you applying and for whom? Are internal or external stan-
dards being applied? Are there “they” and “us” considerations involved in selection?
Do you need help or just need to finish, and, if you just need to finish, is your successor
going to curse you by name daily?
Learning objectives for this course are to:
• Assess what controllers and programming software are in use.
10
Tips on how to choose industrial controller hardware, software
 Back to TOC
• Determine present and future controller Presenters in the in the webcast, “How to choose
industrial controller hardware, software,” from
hardware and software needs.
Control Engineering are Jon Breen, owner,
Breen Machine Automation LLC (BMAS), Frank
• Examine criteria in place for vendor selec- B. Lamb is founder of Automation Consulting
LLC and Eelco van der Wal, managing director of
tion, and if they are meeting your needs. PLCopen. Courtesy: Breen Machine Automation,
Automation Consulting, PLCopen and Control
• Consider the post-programming future? Engineering webcasts
Will the architecture allow updates?
• Learn from examples showing a more supportable hardware-software controller future.
Poll questions during the webcast will benchmark participants’ progress on the topic.
Webcast is moderated by Mark T. Hoske, content manager, Control Engineering. Ex-
pert presenters are:
11
• Jon Breen, owner, Breen Machine Automation LLC (BMAS).  Back to TOC
• Frank B. Lamb is founder of Automation Consulting LLC and creator of The Auto-
mation Primer blog and The Automation Academy, online system integration and
industrial automation training site, which includes teaching PLC, HMI and SCADA
programming.
• Eelco van der Wal is the managing director of the worldwide association, PLCo-
pen, with headquarters in The Netherlands, Europe.
Industrial controller, PLC assessments for hardware, software

In the webcast, Lamb explained that before an upgrade, it’s important to assess what is
in place have to better determine what is needed. Here are six considerations, and he
gives examples to explain further.
1. Plants often don’t have data or complete data. This step probably requires an on-
site visit.
2. Firmware and software revision numbers are important. Firmware and software
versions often must match. Customer may not have support for the latest soft-
ware.
3. Older hardware may not be supported by newer software. Customer may not sup-
port their own assets at all.
4. Don’t forget auxiliary software, such as network configuration!

12
 Back to TOC
5. It’s easy to miss facilities controllers and Assessing where industrial controllers and related
software reside requires investigative work,
devices, such as building controllers.
explained Frank B. Lamb, founder of Automation
Consulting LLC, in the webcast, “How to choose
6. Detective work may be needed beyond industrial controller hardware, software,” from
Control Engineering. Courtesy: Automation
control cabinets: Control may be distrib- Consulting and Control Engineering webcasts
uted, “on machine” solutions.
Industrial controllers: PLC selection advice

Breen said PLCs and programmable automation controllers (PACs) usually are DIN-
rail-mountable plastic or metal boxes enclosing the electronics. Control chips archi-
13
tecture might be custom system on a chip (SOCs), field-programmable gate array  Back to TOC
(FPGA)-based, PC central processing units (CPUs), or a combination. Input/output (I/O)
connections can be local on the PLC and/or via a network. Connectivity often is via
Ethernet or by USB. Breen offers more on PLC purchasing, PLC languages, PLC pro-
gramming, PLC functionality, PLC integration with IT systems and related PLC topics.
PLC selection advice from Breen includes looking for:
• Broad software compatibility – Programming software that’s backwards compatible

with older product versions and cross compatible with multiple lines of controllers
is very helpful. It means you don’t need to scramble for the right version every
time you need to support something. OS support also helps. For example, soft-
ware that’s only supported on Windows 11 would be inconvenient because most of
us are still running Microsoft Windows 7 or 10.
• Easy to manage software – I can tell you for at least one PLC manufacturer, I have
30+ versions of PLC software installed on my laptop. That’s a nightmare to man-
age. I would much prefer to see one programming platform supported for 10 be-
fore a manufacturer launches another major version. I would also like to see easier
licensing. Many manufacturers go to great lengths to make sure you can’t steal
their software, and in doing so, they’ve made it hard to get the software to work in
the first place.
• Strong programming lifecycle management – Look for a version control system

with good differencing tools and multi-user support. That makes it easy to docu-
ment program changes or go back in time if they didn’t work out so well.
14
 Back to TOC
Jon Breen, owner, Breen Machine

• Flexible, powerful, efficient programming tools Automation LLC (BMAS), included
– How quickly can you write a program? How discussion of PLC programming languages
readable/maintainable will it be? How many in the webcast, “How to choose industrial
controller hardware, software,” from
times do you want to reinvent the wheel on Control Engineering. Courtesy: Breen
one project? This is a deep topic, but know that Machine Automation and Control
the tools are out there, and they differ hugely Engineering webcasts
between manufacturers.
• Strong support – Until the robots take our programming jobs, humans will have to
be able to learn and use these systems. Any PLC worth considering will have good
15
 Back to TOC
support from the manufacturer and/or distribu- Programming efficiency can be improved
tor – applications, technical, phone, in person, with use of code libraries and other tools,
according to Eelco van der Wal, managing
and online. director of PLCopen, in the webcast, “How
to choose industrial controller hardware,
software,” from Control Engineering.
PLC software advancements to over- Courtesy: PLCopen and Control
come code complexity Engineering webcasts
Van der Wal noted that with huge advancements
in controller hardware, many are more dependent on software and suffer because
of the resulting increased software complexity. Doubling the lines of code more
than doubles complexity, he said. Controller software and software development
requires more attention to managing complexity. PLCopen supports modern soft-
16
ware development processes that provide a structured approach. This can happen,  Back to TOC
van der Wal said, with:
• Modern software development processes
• Libraries of re-usable components
• Open standardized interfaces
• Application programs independent from hardware and architecture.
PLC and industrial controller programming can benefit with attention to software struc-
turing, decomposition, reuse, encapsulation and abstraction, van der Wal said. By
using function block libraries, application programs can be smaller and easier to up-
grade. PLCopen has function block libraries for logic, for motion, for safety and com-
munications.
Jon Breen, Frank Lamb and Eelco van der Waal

Jon Breen, Breen Machine Automation; Frank Lamb, Automation Consulting; Eelco
van der Waal, PLCopen
17
PLC module coordinates real-time
data in coal shipping application  Back to TOC
A coal shipping company improved their supply chain and operations by

reducing inefficiency and waste with PLC modules.
N eptune Bulk Terminals handles a large portion of the Canadian steelmaking (met-
allurgical) coal exported to overseas markets annually, and it is an important con-
tributor to the Canadian economy. Reducing environmental impact, costs and process-
ing times are high priorities across the supply chain.
However, an inability to know or control real-time status and real-time routing can lead
to inefficiencies, taking the form of missing customer commitments, lower capacities,
higher costs and avoidable shutdowns. Streamlining delivery of this information often
involves bridging the gap between operational technology (OT) and information tech-
nology (IT), enabling users to maximize efficiency and boost visibility across the ship-
ping plant.
Until now, many manufacturing and shipping plants have relied on manual processes,
or software and computers, to integrate programmable logic controllers (PLC) to busi-
ness systems to manage operations. However, these tools come with challenges asso-
ciated with hardware and software compatibility, security risks and system interdepen-
dence. Fortunately, there are industrial built-for-purpose tools that eliminate the PC
and customer software code and let users seamlessly integrate IT and OT in a way that
enables bi-directional data exchange between enterprise systems and PLCs, unlocking
many benefits across the supply chain.
18
PLC module coordinates real-time data in coal shipping application
 Back to TOC
QCA Systems LTD recently won an award for success- Figure 1: The main routing interface,
fully integrating its OT and IT systems in a coal ship- which shows most of the routing
information transacted to the SQL
ping plant. With more than 30 years of experience, database. Courtesy: Softing
QCA is Canada’s most dominant electrical engineering
and automation company in the bulk material handling industry. To improve end users’
productivity and reduce overall manufacturing costs, the company uses its experience
integrating industrial and commercial systems, making them secure and creating re-
al-time and historical views of site process data. In one case, they used an industrial,
built-for-purpose, in-chassis PLC module to improve efficiency.
Changing conveyor routes and cargo train conditions

In this application, steelmaking coal comes in from cargo trains, is processed on-site 19
and loaded onto large Handymax or Cape-size vessels. Inside the terminal, shipments  Back to TOC
are processed through a network of conveyors that must accurately move the coal to
and from the cargo transports. The conveyor system, which consists of multiple routes,
is crucial to the successful distribution of shipments to the target destinations.
However, these routes are subject to change. Variables such as the volume of imported
coal, different grades or load capacity of vessels, can influence the path of a shipment,
causing it to deviate from the predetermined route. The shipping plant needed the
most accurate real-time information available to successfully adjust its procedures to
these evolving circumstances.
Although PLCs stationed along the conveyor routes control the movement of coal, in
the event of a process interruption, there was no visibility into a faulty conveyor’s re-
al-time status. There was also no visibility into other nearby conveyors with spare ca-
pacity, and no visibility into the higher-level business system, which managed the en-
tire process and logistics.
At this site, PLCs communicated to a single PLC that controlled the routes. In order to
improve efficiency, the company needed a lean site-wide management system at the IT
business level, and this site-wide management system needed to be integrated to the
routing PLC at the OT control level.
Improving operations with an in-chassis PLC module

To integrate the site-wide management system into the PLCs, QCA selected tManager,
an industrial, built-for-purpose, in-chassis PLC module that installs in ControlLogix
PLCs. This device acts as the messenger between the PLC and enterprise system, such
as Microsoft structured query language (SQL) databases, and eliminates the PC server,
20
 Back to TOC
software and scripting oftentimes required to orches- Figure 2: Dumper Automatic

trate transactions between the two. By connecting the Equipment Identification (AEI) graphic
showing the data transacted to and
lean management software system to the enterprise from the PCS database to the PLC.
SQL database and connecting the PLCs to the SQL Courtesy: Softing
database, it was able to transport critical information
bi-directionally to PLCs, enabling personnel in the coal shipping plant to modify their
plans with the most accurate and up-to-date information available.
Previously, plant operators could only monitor the expected arrival time and availability
of inbound trains and outbound ships, creating operational dead spots if the wrong
train arrived for drop-off or the conveyor stopped processing for a single route, for ex-
ample. The module addressed these issues by providing greater operational visibility.
21
 Back to TOC
Routing data is moved from the PLC and stored in a Figure 3: The SQL sends an expected
car list to the respective PLCs. When
database or other cloud application. In the event of a a coal railcar enters the dumper, it is
process malfunction, the module overwrites the old sta- read by the AEI readers and matched
tus information in the database to reflect the new route with the car details from the expected
car list. Once dumped, the actual
status. In turn, it gets new status information from the production data for that railcar is sent
database and writes this to the PLC to reroute traffic. to the PCS database using tManager.
Not only does this strategy limit the risks associated Courtesy: Softing
22
with misplacing a product, it also provides detailed real-time information, following the  Back to TOC
product from the beginning to the end of the cycle.
Centralizing and connecting information with machine control reduces manual processes,
increases overall plant efficiency, reduces risk, improves customer commitments and can
even lead to valuable metrics for analyzing processes for overall process improvements.
The module also avoids potential pitfalls associated with using PCs and custom cod-
ing to integrate business systems with industrial PLCs because it requires no updates,
provides better security and is tied to the controller. It also avoids relying on the com-
plicated dance between servers, software and networks for planning and execution.
Improving operations management and supply chain

In this application, the module controls the company’s site-wide routing process, while
a second and third module manage the importing train systems, as there are two railcar
dumpers in this application — each with its own system. Thanks to these devices, the ship-
ping plant now has a more holistic view of its entire shipping process, allowing it to adapt
on the fly. Not only is it less complex, it requires no coding, programming or servers.
Thanks to QCA’s engineering and automation expertise in designing and implement-

ing this intelligent routing system using a built-for-purpose OT to IT connectivity solu-
tion, the plant has improved its efficiency without having to expand its facility’s foot-
print that can be implemented in future projects.
Deane Horn
Deane Horn is director of product management at Softing.
23
Modern development tools for industrial automation
Git-Based Source Control for PLC Programming
Track all changes to PLC code

See the differences between versions
Accelerate review processes
Enable engineers to work simultaneously and on the same codebase
Device Backup and Change Detection
Automatically back up running control programs, including PLCs,

robotics, vision systems, and network switches
Visualize the data in one central location
Detect any unauthorized changes
Visually compare code for Àuick troubleshooting and recovery
Learn more and sign up for a trial at www.copia.io

Copia renders industrial code from Rockwell Automation®, Siemens®, CODESYS®,
Beckhoff®, Schneider Electric®, WAGO®, ABB®, and Lenze® in a web browser.
Intro to Git-Based The Value Of Version Control For
Industrial Automation
Version Control
Good version control practices are essential for efficient
code development. They ensure that you, your team,
and your company can track changes to files over time,
for Industrial understand why the changes were made and by who,
and revert to specific versions of code if needed. When
Automation a robust version control system is implemented correct-

ly, teams can focus more on the development activities
instead of searching for and investigating code changes.
As more engineers are assigned to the project or more
time passes between project activities, the benefits of
proper version control increase. Less time is required to
understand how and why a project arrived at its current
state.
For an industrial automation developer, a sound version

control system will ensure you can always answer the fol-
lowing questions:
• Where is the latest version of the PLC code, and can I

access it without calling another developer?
• Is this version of code the same as that has been de-

ployed onto the PLC?
Intro to Git-Based Version Control for Industrial Automation
• Was the latest version reviewed/approved by the proper people?  Back to TOC
• What has changed between this file and the previous version? Who made the
change and why?
• Can I control which persons can access the files at different stages of the PLC
code’s lifecycle?
While there are many different types of version control systems, this document focus-
es on Git, which dominates the software industry with over 80% market share and is
used by ~100 million developers.
What is Git?
Git is a mature and actively maintained open-source tool created in 2005 by Linus
Torvalds (the founder of Linux). It is now the most widely used modern version con-
trol system globally. There were several reasons why Git became the standard.
1. Git is distributed, meaning files and history are stored locally and in a central
repository. This characteristic enables engineers to work without network access.
2. Git is fast. Since history is stored locally on your device, changing versions is
nearly instant.
3. Git is secure. Git uses a hashing algorithm that ensures that every edit is trace-
able. It is impossible to change a file or directory without Git knowing.
26
How is Git Different from GitHub?  Back to TOC

Git is an open-sourced, distributed version control tool. GitHub is a cloud-based
platform built around Git. GitHub hosts a Git repository in the cloud, and is the most
popular way people utilize Git source control. It started as a for-profit company, and
Microsoft purchased the company in 2018. Other platforms built around Git include
GitLab, Bitbucket (Atlassian), AWS CodeCommit, and Copia Automation. When we
talk about the popularity of Git version control, we refer to the total users of the vari-
ous Git providers and the open-source tool.
An important thing to note is that Git is often used via a command-line interface but
has a simple graphical user interface (GUI). Most 3rd party Git providers - like GitHub
and Copia, include a more comprehensive graphical user interface that simplifies Git
tasks and, in the case of Copia, adds value when dealing with specific file types. (For
example, Copia is tailor-built to show ladder logic and function block diagrams when
working with industrial Automation files).
Today’s Manual Process Is Prone To Errors

For an industrial automation professional who is not familiar with Git, it may be eas-
iest to understand if you compare it to the widespread and manual practice of using
an archive folder to manage industrial automation files.
The typical Archive Folder Workflow has the following steps:
1. The controls engineer creates project files on their local computer, using an
installed Integrated Development Environment (IDE) (such as Rockwell Auto-
mation® Studio 5000 Logix Designer® or Siemens ® TIA Portal). The names of
27
the files are often a user created mix of a project name, version, and engineers  Back to TOC
initial (.i.e Mixer_DAH_V1.1)
2. Edits are stored by overwriting the previous file (Save), or copying and renaming
the new files (Save As).
3. When work is completed to a significant state, the file or entire project folder
may be zipped and copied to a central location for sharing and backup.
4. If another team member needs to access the files to review or make changes,
they need to download them to their local hard drive and use their development
environment to view and edit the files.
It is not uncommon for controls engineers to “Copy and Rename” to manage a file’s his-
tory, resulting in a list of similar files distinguished by file names and modification dates.
Unfortunately, there are many problems and limitations with this workflow. For example:
• There is no inherent information on why a file was updated or changed. Addi-

tional work is needed to document and communicate changes.
• Project organization is based on manually naming files, which is prone to human

error.
• There is no easy way to see the difference between file versions. Some IDEs pro-
vide this capability, but only for their specific file types.
28
• Local files are  Back to TOC

not backed up
regularly. Work
is often lost,
and the latest
version of a
project may
not be in the
archive folder.
• Collaboration
Prone to error, most organizations rely on file copies
is limited. If teammates copy the
with file names to indicate which version is the latest.
same file from the central location
and make changes, they cannot easily
merge their work.
• It is difficult for managers to understand the progress made on a project since

the work is usually kept on local machines.
• There is no inherent method for reviewing and approving files.
• Setting access permissions for specific files can be challenging.
• For large files, copying, pasting, and eventually uploading can take a signifi-
cant amount of time. This fact may decrease the frequency at which projects are
backed up.
29
Git alleviates these disadvantages. A basic Git-based workflow has many similarities  Back to TOC
to the Archive Folder Workflow workflow. Work is done locally, changes are saved
and committed to the file’s history, and then these committed changes are synchro-
nized to a centralized location. There are significant benefits as Git removes the
need to copy, move and rename files manually. Git stores versions of the project and
provides rich context on who-what-and-why changes were made.
Git Glossary | Common Terms

Many people struggle with the Git terminology. Here is a quick glossary of terms to
understand before discussing basic Git workflows:
Repository (Repo)
A “repository” or “repo” is simply a folder structure stored in Git. The “root” of a
repository is the base folder you want to store. A repository is different from a typical
directory only because it stores context about the changes to the root folder and all
of the subfolders under the root.
Local Repository
A copy of the repository local to your workstation.
Remote Repository
A copy of the repository that is centrally located in the cloud or on a server. It is
where you push changes for collaboration and backup.
Branch
A branch is a diversion from the main working project. By creating a new branch, the user
30
can create a new version of the repo or experiment with changes that will not affect the  Back to TOC
base code. The most recent commit is considered the head of that branch. If you are hap-
py with the changes in one branch, you can merge those changes into another branch.
Main (Master) Branch

Akin to the trunk of a tree from which all other branches start. The main branch is
where the final, error-free code is stored. Every Git repository has a main branch. You
can create new parallel branches off the main branch, empowering you to do work
without affecting that mainline.
Clone
A copy of an existing repository. The clone can be made as a branch or downloaded
to your local repository from a remote repository. You are required to create a clone
to work on a repository.
Commit
A commit is a recorded change to a file or set of files. It is often thought of as a
snapshot or version of your repository. Commits only create a snapshot in your local
repository. To synchronize these changes to the remote repository, Push.
Pull Request (PR)

A pull request (PR) occurs when you alert others about or request a review of a
change you’ve pushed to a remote repository. The changes can be discussed, re-
viewed, and commented on, with followup commits added before the changes are
merged into the main branch. The intent of the pull request is to merge changes into
the main branch.
31
Push  Back to TOC

A push is a command used to add your commits from your local repository to a re-
mote repository. A push is the opposite of a fetch.
Merge
Merging combines two branches. Typically, commits made to a branch are merged
into the main branch after being reviewed via a pull request. In some organizations, a
project maintainer or manager is responsible for approving merges.
The Basic Git Workflow

Here are the steps of a Basic Git Workflow for an Industrial Automation project:
1. A central repository is created on a server. This server will be cloudhosted for

most Git providers (GitHub, Copia, etc.).
2. The repository is then cloned to the control engineer’s local machine. It will ap-
pear on the local PC as a standard Microsoft ® Windows ® folder.
3. The engineer creates their automation files using their local IDE (such as Rock-
well Automation Studio 5000 Logix Designer), saves the file in the local reposito-
ry, and commits these changes to the file history when ready.
4. When a development milestone is reached, or the engineer believes it is ap-

propriate, the engineer will push their committed changes to the central re-
pository.
32
5. Meanwhile, teammates who have also cloned the central repository locally can  Back to TOC
“pull” the updated files to their local repository so that they are always working
with the latest files.
You can see these steps outlined in the diagram below:
In a Git workflow, file names stay

the same, and commit history is
automatically tracked. A simple set of
pull and push commands ensure that
everyone has access and is working with
the latest version.
33
A PLC file’s history can be viewed using a Git commit graph. Notice that any previous  Back to TOC
commit can be retrieved if needed.
With Git, each committed change is stored

with context and can be visualized as a
There are some subtle things worth mentioning: node along a main branch of code. A
simple revert command can be used to
access previous changes.
• As changes are made, file names can stay the
same in Git. There is no reason for the engi-
neer to have to use the file name to describe the state of the project (i.e. Apex_
labeler_DAH_Final.ACD). Git tracks the difference in each commit for you.
• Tasks like creating and cloning repositories, committing, pushing, and pulling are
fast and usually only take a few mouse clicks. The Git workflow is easy to execute.
• Git never deletes or overwrites files, so you can always access your historical
work if needed. If you accidentally removed a rung and saved the file, you can
simply revert to an earlier version. It’s like a post-save undo! 34
• A persistent internet connection is not required. You can work locally and then  Back to TOC
push changes at a later time. This is quite helpful when making code changes on
field-based devices.
Why Hasn’t Git Been Widely Adopted by PLC

Programmers (Yet)?
We mentioned that a remarkable benefit of Git version control is tracking when files
change and showing what changed.
Git does this by displaying the contents of file versions and highlighting the differ-
ences in a diffing process.
Diffing is relatively fast and
straightforward because most
traditional software develop-
ment uses text-based pro-
gramming languages (includ-
ing Python, JavaScript, Java,
C#, C, and C++).
An example of a Git “diff”

is provided below. The red
items indicate lines of delet-
ed code, and the green items
represent new code that has Git visually displays the changes
been added. between commits in text-based files.
35
Deleted code is shown in red, while
additions are shown in green.
Unfortunately, PLC programming evolved quite differently than traditional software  Back to TOC
programming. While there are some text-based languages for PLC Programming,
most are done in visual languages like Ladder Logic and Function Block Diagrams.
This problem was compounded because many PLC vendors use different binary file
formats. The inability of standard Git to display these languages reduced much of its
value for many controls engineers.
So to be clear, for most industrial controls projects, Git can tell you when and who
changed files but not show you how those files changed. The lack of this significant
benefit has slowed Git adoption.
Git relates that PLC files have changed,

but does not visually show differences
between file states. 36
Copia Automation to the Rescue  Back to TOC

Copia Automation was founded to bring modern developer tools to industrial auto-
mation professionals, unlocking the productivity gains already realized in traditional
software development. They have started by solving the issue around visualizing and
diffing PLC code changes when using Gitbased source control.
Copia toolsets empower engineers to visualize PLC code in ladder logic, function
block diagrams, and structured text languages. Copia can visualize code from Rock-
well Automation ® Studio
5000 Logix Designer ®,
Siemens® TIA Portal,
ABB® Automation Build-
er, Beckhoff® TwinCAT®,
Lenze ® PLC Designer,
Wago® e!COCKPIT, COD-
ESYS®, and additional
vendor support. Teams
can follow a consistent
workflow no matter what
PLC vendor they choose.
It is essential to under-
stand that Copia renders
the PLC code in its desk- Copia visually displays changes
top app and web browser. This capability provides between commits to ladder logic files.
incredible freedom to automation teams and accel- Deleted rungs are displayed in red,
and additions are shown in green. 37
erates code review and discussions. Consider a junior engineer developing a section  Back to TOC
of code that controls machine safety and finishes their task late in the day. With only
a web link, a manager who needs to review the code can securely log in to the Copia
repository from a home computer and see the latest changes directly in a web browser.
Advanced Git Workflows to Unlock Greater Value

Although we described a basic Git workflow, Git supports advanced workflows that
add more control and improve collaboration. These workflows are centered around
concepts known as Branching and Merging.
An easy way to understand the concept of branching is to envision that every devel-
opment project has a main branch where the final error-free code is stored. Every
commit represents a vetted change that purposely improves the code.
Git allows you to create a parallel branch from the main branch when adding new
features and creating bug fixes. This branch enables you to make changes without
disturbing the main branch. If your code changes are successful, you can merge the
changes back into the master branch; if they are not successful, you can delete them.
Using this branching and merging process gives your team greater control over when
the main branch is changed. For example, rules can be developed and enforced so
only project leads can merge code into the main branch, ensuring that all changes
are reviewed and approved.
Another benefit of this workflow is that it keeps the project development history
clean and easy to understand. Significant changes to the production code are docu-
38
mented in the main branch, while work in progress is tracked and stored within de-  Back to TOC
velopment branches.
Git branching can ensure that any work

in progress (development branches)
One of the most powerful aspects of Branching and
can be completed and reviewed
Merging is the ability for multiple developers to work before merging with the production
on the same project simultaneously. Each develop- code (main branch).
er can create individual development branches, and

when their work is complete, they can use the merge command to stitch their work
together into the main branch. Branch and merging allow you to add more engineers
to a job to meet tight deadlines.
You might ask, “What happens if two engineers change the same line of code and
then merge - and which change will be accepted?”
Git handles such situations with tools to resolve merge conflicts. The project lead can
39
see both changes and choose the better one. This ability is another reason why visu-  Back to TOC
alizing differences between commits is so essential during the code review process.
What is a Pull Request? Development branches can exist

simultaneously, allowing multiple
A service call with a PLC programmer is needed
engineers to work together on the same
after machine commissioning. The programmer code. Merging can combine all work
can create a branch and work on code. Upon com- together into the main branch.
pletion, they can notify the project lead that the

branch is ready for review and merge. To do this, they create a pull request.
A pull request occurs when you alert others about or request a review of a change
you’ve pushed to a remote repository. The changes can be discussed, reviewed, and
commented on, with follow-up commits added before the changes are merged into
the main branch. The intent of the pull request is to call for a merge into the main
branch.
40
Branching and Merging, Tailor-Built for Industrial Automation  Back to TOC

We have stated that Copia Automation provides specific tools to visualize ladder log-
ic. The same visualization
is used when handling
merge conflicts. Copia
will display the rungs in
questions and prompt the
decision-maker to choose
which change is preferred
if multiple engineers
change the exact area of
code.
Copia understands that

thorough code review,
careful pull request ap-
proval, and thoughtful
merge conflict resolution
are essential for produc-
ing the highest quality
code. Copia allows teams
to add comments at the
rung level to discuss
and document deci-
sions during a pull request. This context, captured If a conflict is detected during a merge,
41
Copia will display the conflicting code and
throughout a project’s lifecycle, can be utilized to
prompt the user to choose a resolution.
train new programmers, ensure consistency, and identify opportunities to improve.  Back to TOC
How Git-Based Version Control Improves Business

Hopefully, at this point, you have a clear understanding of Git-based version control
and the features that are meaningful to industrial automation professionals, specif-
ically PLC programmers. When we talk about the value to a business, the primary
benefit is centered around employee productivity and shortening product time-
lines. With Git-based source control implemented, all individuals will spend less
time searching for the files and investigating how files differ during their lifecycle.
That time savings can be reinvested in high-value work developing innovative and
high-quality code.
Branching and merging enable multiple team members to work on the same automa-
tion project simultaneously. This practice has the potential to be a substantial com-
petitive advantage for a company and ensure tight project deadlines are met.
The increased collaboration of Git-based version control also enables the business to
utilize their most skilled people more efficiently. Senior control engineers can quickly
review more junior engineers’ work continuously via a web app and document their
feedback to help accelerate team training. Improved code quality is another signif-
icant benefit of a Git-based version control system. Using visual diffing capabilities
allows errors to be detected more readily. Formal pull request procedures ensure
that only authorized people can change the production code.
Finally, a solid Git-based version control system can save a business thousands when
dealing with unexpected operational problems. If a major incident disrupts manu-
42
facturing, the last good version of the code can always be found quickly and used to  Back to TOC
restore service.
Summary and Next Steps

Git is the ubiquitous source control solution for software development, and its use
has accelerated the speed at which code is developed and deployed. It is proven to
shorten development timelines, increase quality, and maximize operational uptime.
While the visual languages and proprietary formats of PLC code have kept industrial
automation developers from realizing the same gains, Copia Automation has made
tremendous strides to remove these challenges. Now, ladder logic and function
block diagrams are supported and can be visualized outside of their development
environments. While saving and storing code is slightly different from the traditional
archive folder workflow, Git-based source control for industrial automation projects is
easy to learn and worth the benefits.
It’s easy to get started with Git. You can find more information and choose to down-
load the open-source version of Git from https://git-scm.com or try a free version of
GitHub at https://github.com/. If you are considering Git for your PLC programming
projects, we strongly recommend signing up for a free trial of Copia Automation at
WWW.COPIA.IO.
43
PLC migration improves uptime
for spice supplier  Back to TOC
A spice ingredient supplier wanted to upgrade their programmable logic

controller (PLC) system and migrate to a more Industrial Internet of Things
(IIoT)-friendly platform.
W hen is the best time to upgrade a decades-trusted programmable logic control-

ler (PLC) system? This was the challenge for a global supplier of spice ingredi-
ents. Their PLC-5 system was commissioned over 25 years ago and, while it performed
well for many years, the outdated platform began experiencing constraints. The ob-
solete equipment was limiting network connections. This led the company to seek a
system integrator that could provide timely PLC migration support using the latest
technology available. Automation Group was recruited to modernize their obsolete
PLC system to a more Industrial Internet of Things (IIoT)-friendly platform.
Programming new PLC system

The first step was reverse engineering the customer’s legacy system and documenting
its current design to address potential risks and how to best program the new system.
Existing diagrams were analyzed and worked extensively with the customer’s person-
nel to further detail device and wiring configurations. This step was crucial to improve
system performance and have an accurate picture of their control environment before
moving to the design phase.
A simplified migration plan leveraging the latest Rockwell Automation technologies.

The global spice supplier’s legacy Allen Bradley PLC-5 system was upgraded to the
ControlLogix platform. An L82E processor was utilized and the old RIO and DH+ net-
44
PLC migration improves uptime for spice supplier
works were changed  Back to TOC

to Ethernet/IP network
communications. Out-
dated Allen Bradley
1336 variable frequen-
cy drives were also up-
graded to Powerflex
525 variable frequency
drives, offering a wide
range of motor con-
trol. Additionally, the
customer’s FactoryTalk View SE screens were updated and Courtesy: Automation Group
consolidated which made the system easier to understand
and operate by plant personnel.
Project results of PLC migration

The project was successfully executed to schedule. The global spice supplier’s focus was
continue their journey to digital transformation and the PLC-5 to ControlLogix migration
accomplished this goal, supporting improved performance, greater uptime, and a more
user-friendly interface. Automation Group staffed the project with four subject matter
experts to provide comprehensive multidisciplinary engineering support in PLC pro-
gramming, FTView SE application programming and networking, as well as drafting and
design. The project team successfully upgraded the customer’s PLC system.
Automation Group
45
Achieving on-stream control
room relocations  Back to TOC
A natural gas processing and compression facility control rooms had to relocate,
which caused many challenges in an application with many potential hazards
during the process. Project included control panel upgrades, communication
digitalization and moving process control and process safety systems.
D ue to potential blast hazards to plant personnel the control rooms of a natural gas
(NG) processing and compression facility had to be relocated to blast-resistant
modules (BRMs). The project required control panel upgrades, communication digita-
lization and moving process control and process safety systems. This complex cutover
for personnel protection needed to be completed without shutting down either of two
interdependent NG production facilities. A shutdown would result in a process upset
at 12 oil production facilities, which relies on the natural gas feed for their operation.
Control room, process control system migration

project challenges
The facility feeds large volumes of compressed natural gas to 12 oil production fa-
cilities through sections of piping up to 5 feet in diameter with compression being
achieved by enormous gas turbines. The number of drawings, valves, interconnecting
wires and control schemes that needed to be evaluated was extensive and complex.
Normal gas operation controls such as turbine controls, panel boards, and valve inter-
faces such as the main gas header valves feeding the plant had to be migrated which
included basic process control systems (BPCS), safety systems, fire & gas (F&G) sys-
tems, halon fire suppressant circuits and emergency shutdown (ESD) circuits. 46
Achieving on-stream control room relocations
A misstep on these critical process control and plant safety systems could have  Back to TOC
brought the facility down, which would have cascaded to downstream facilities that
rely on the natural gas for operations. Furthermore, the NG facility equipment spanned
50 years of modifications, and many upgrades which were needed to universalize and
modernize the many generations of equipment, including digitalizing hardwired sig-
nals into a new programmable logic controller- (PLC) based BPCS.
E-stop migration, process isolation safety complications

The greatest challenge was migrating the hardwired emergency stop (E-stop) circuits
to the new control room with minimal transition time and without a widespread outage.
In fact, because of the hazards and complexities involved in a complete shut down
and restart, the NG facility had only been shut down twice since being placed into
service many decades earlier, and it had been over a decade since the last complete
outage. E-stops are used by operators as a last resort in response to a critical process
excursion. The E-stop circuit, when tripped by the operators, opens valves to the flare
relief system, closes isolation valves, and shuts down running equipment. Complicating
matters is the fact E-stop circuits are fail-safe designed, which means if any circuit is
opened, the E-stop actions are triggered.
Project lessons learned:

System integration project management
It became apparent having a single point of contact for project management was key to
planning and developing a cutover strategy starting from the early appraisal stages of
the project to the final execution stage. Detailed advanced planning was needed with
careful consideration to the scope of this complicated project and the numerous stake-
holders involved. Any shortcut or attempt to skip a project step could have had potential
47
 Back to TOC
consequences to an effective cutover, so understand- The local FAT lab was instrumental
ing the big picture and high-level activity as well as in enabling the team to confirm how
equipment worked, verifying detailed
delegating specific tasks to specific people from a FAT plans and test procedures.
central focal point became essential for success. Chan- Courtesy: aeSolutions
neling communication through single points of contact
ensured all input, concerns and feedback were received and addressed. 48
Understanding the many stakeholders involved was important. The project team was  Back to TOC
an extensive network of people with different backgrounds and responsibilities, and
the systems integrator helped coordinate and integrate the needs and influences from
affected stakeholders. All groups needed to collaborate to identify long-term operabil-
ity constraints and/or mitigate potential future operability issues with the reconfigured
system. Integrating moving parts to strategize the project execution was key to avoid-
ing siloed groups of disciplines.
Six steps for project success included control system, safety

system cutover, factory acceptance test, control panel upgrade
The system integrator designed the control room and took responsibility for all stages
of the project, managing tasks from conceptual and preliminary engineering to de-
tailed design and managing on-site activity and personnel during the complex cutover.
Beginning with a comprehensive survey of the existing facilities, the systems integrator
cataloged equipment and systems that needed to be relocated, identified stakehold-
ers and resources involved, and then created a detailed plan for cutover without re-
quiring plant downtime. The six steps for the project were:
1. Performed a detailed option analysis to evaluate potential best solutions.
2. Analyzed existing terminations and every wire to understand what it does and
temporary bypasses to be put into place; maintained a well-documented log to
track what had been completed.
3. Developed step-by-step cutover procedures and checklists and an integrated

schedule that identified specific people and detailed daily tasks over the year
49
leading up to the cutover of both NG facilities. Impacted stakeholders included fa-  Back to TOC
cility engineers, operators, support staff, design team, contractors, vendors, con-
struction crew, and IT networking crew. A comprehensive responsibility matrix was
maintained to coordinate all tasks required.
4. Developed a contingency plan to guard against emergency events and mitigate

risk of valves changing position during cutover process for safety purposes; had
personnel stationed at all the critical valves during the cutover process to monitor
and respond to potential process hazards; processing natural gas is an exercise in
precision, and even the smallest changes in pipeline pressure, flow rates, tempera-
ture, and gas composition can have huge impacts.
5. Set up a local integration center, i.e., factory acceptance test (FAT) lab, to con-
vene equipment and everyone involved and determined ways to install additional
panels. They also designed, fabricated, tested and provided new control panels
needed for the PLC and control systems as well as safety systems such as E-stops
and F&G system. They also developed a scheme of transitioning existing termina-
tions to new termination locations without causing a shutdown and prepared all
personnel involved within the FAT lab to ensure a smooth cutover process during
implementation in the field.
6. Managed on-site activities helping direct the cutover process while implementing
the cutover plan, including directing facility operators, engineers, support staff,
construction and information technology (IT) staff.
50
Project results: Project management, standardization, control  Back to TOC

panels
The systems integrator’s role evolved from system integrator to becoming the focal
point of coordinating schedules and staffing and choreographing the entire cutover
project. aeSolutions started by surveying the existing equipment and systems. By
having a single point of contact for project management, the client benefited from
standardization of approaches and technology, a higher degree of coordinated activity,
and a shortened timeframe. The integrator developed an execution strategy and found
ways to integrate multiple teams into the plan while handling the conceptual engineer-
ing, preliminary engineering, detailed design, and manufacturing and implementing
the required components.
The local FAT lab was instrumental in enabling the team to confirm how equipment
worked, verifying detailed FAT plans and test procedures, and developing methods
to (dis)connect test panels with everyone in the same room. Equipment was evaluated
during and after the assembly process to verify it was built and operated in accordance
with design specifications. The FAT lab provided an off-site opportunity to reconcile and
unify all the moving parts involved with the unit before the equipment was shipped to
the site. This integration strategy saved time and travel costs to cutover the controls on
a NG operating plant without impact to production. In the end the project achieved its
two objectives: 1) the NG facility employees were relocated to the new BRMs and 2) the
project was completed without a shutdown or process upset of the operating facilities.
Lessons for future projects: Front-end loading, codes

and standards
As a result of the success of this project, the integrator established a project develop- 51
ment team dedicated to scope development and planning for complex projects. This  Back to TOC
team is involved in the early stages of complex projects to guide clients to a project
vision, identify risks, advise on codes and standards, develop and clarify scope, and
consult and check in on project progress.
This upfront involvement with focus on front-end loading (FEL) what’s practical, paves the
road for project managers and engineers to deliver on the project vision, manage the
risks, scope, schedule, budget, and expectations. It also coordinates across disciplines.
In turn, the work can be executed by the technical leads and discipline specialists with
minimal obstacles and yield a maximum quality product that is safe, intuitive, reliable,
maintainable, fit for purpose and adheres to standards and best practices.
Ted Hoffman and Charles Mills

Ted Hoffman, PE is senior project development engineer at aeSolutions. He is a pro-
cess controls system engineer and project manager with over 32 years’ experience.
He has demonstrated success as a professional, goal-oriented engineer with a proven
track record in project assessment, conceptual and detailed design, programming,
field start up, project leadership and technical team development. Charles Mills is an
automation control specialist with aeSolutions. He has more than 37 years of expe-
rience as an automation/controls engineer; fourteen in a plant and equipment engi-
neering environment at two manufacturing companies, two and one-half in conveyor
control systems at a system integrator/OEM and more than nineteen in a consulting
engineering role.
52
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PLCs

3 — A new future for process control systems

9 — AutomationDirect is your TOP Choice for affordable PLCs

10 — Tips on how to choose industrial controller hardware,

18 — PLC module coordinates real-time data in coal

25 — Intro to Git-Based Version Control for Industrial

44 — PLC migration improves uptime for spice supplier

46 — Achieving on-stream control room relocations

Industrial control systems need to change and future process automation

M any challenges have confronted industrial companies in recent years, rang-

Adapting for the future

Because this scheme moves non-core functions to a connected-yet-separate digital

between 10% and 40%.

Digital technologies help  Back to TOC

Another challenge is the

instruments can have their

2304-ElectricalContractor-CompanyBranding-MAG.indd 1 3/7/2023 11:09:57 AM

New business models for DCSs  Back to TOC

New business models, including software-as-a-service (SaaS) and platform-as-a-ser-

Choose the right programmable logic controller (PLC) hardware and

Learning objectives for this course are to:

• Assess what controllers and programming software are in use.

Will the architecture allow updates?

• Learn from examples showing a more supportable hardware-software controller future.

Industrial controller, PLC assessments for hardware, software

4. Don’t forget auxiliary software, such as network configuration!

Industrial controllers: PLC selection advice

PLC selection advice from Breen includes looking for:

• Broad software compatibility – Programming software that’s backwards compatible

• Strong programming lifecycle management – Look for a version control system

Jon Breen, owner, Breen Machine

• Modern software development processes

• Libraries of re-usable components

• Open standardized interfaces

• Application programs independent from hardware and architecture.

Jon Breen, Frank Lamb and Eelco van der Waal

A coal shipping company improved their supply chain and operations by

Changing conveyor routes and cargo train conditions

Improving operations with an in-chassis PLC module

software and scripting oftentimes required to orches- Figure 2: Dumper Automatic

Improving operations management and supply chain

Thanks to QCA’s engineering and automation expertise in designing and implement-

Git-Based Source Control for PLC Programming

Track all changes to PLC code

Device Backup and Change Detection

Automatically back up running control programs, including PLCs,

Learn more and sign up for a trial at www.copia.io

Automation a robust version control system is implemented correct-

For an industrial automation developer, a sound version

• Where is the latest version of the PLC code, and can I

• Is this version of code the same as that has been de-

How is Git Different from GitHub?  Back to TOC

Today’s Manual Process Is Prone To Errors

The typical Archive Folder Workflow has the following steps:

• There is no inherent information on why a file was updated or changed. Addi-

• Project organization is based on manually naming files, which is prone to human

• Local files are  Back to TOC