IAA August 2010

August 2010

www.iaasiaonline.com

MICA(P) 039/07/2010 | ISSN 0219/5615 | PPS 1561/06/2011 (028597)

Precise Detection

Sensors With

M2M:

Rugged Design

SCADA:

Easy Field Access

Water Management:

Progressing Performance

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contents AUGUST 2010

ISSUES & INSIGHTS

20 M2M: Rugged Design

Demanding technology that can operate reliably in harsh environments, with an affordable price tag. By Bernard Lee, MD, Procuro Asia Pacific

CONTROL POINT

26 Water Management: Progressing Performance

Improving engineering efficiency and optimising energy costs while expanding sustainable water management systems. By Chris Smith, director, SCADA Business; Eduardo Ballina, Global Industry Solutions – Water and Wastewater; Maryanne Steidinger, director, Advanced Applications Product Marketing, Invensys Operations Management

30 Distribution Management Systems: Smartness In Control

Integrated SCADA/DMS innovations place analysis and control functions in the hands of grid operators. By Marina Ohrn and Hormoz Kazemzadeh, ABB Power Systems, Network Management

36 SCADA: Easy Field Access

The World Wide Web opens windows for technologies that allow operators to remotely monitor equipment and facilities.

By Alex Hsiao, director, Advantech Green Energy Product Division

Software & Networks

39 Warehouse Security: Eyes, Ears…& Minds

Security cameras are evolving from simple surveillance to gathering vital business intelligence. By Oh Tee Lee, regional director, South Asia Pacific Region, Axis Communications

Instrumentation & Measurement

42 Precise Detection With Sensors

Ultrasonic sensors provide a means to accurately perform measuring and quality checks – even in confined spaces. By Daniel Dossenbach, product manager Sensor Solutions; Sarah Jess, Baumer

45 Photoelectric Sensors: Working Reliability

Sensors need to be easy to set up, adjust and perform effectively in a variety of environments. By Adrian Schwarz, product unit manager, Business Unit Photoelectric Sensors & Fibres, Sick

SECTOR SPOTLIGHT Fast Forward .

46 Logistics: With Storage

As businesses in Asia progress in the seafood industry, the advancing technology provides better solutions for storage when dealing with rising demands. By Brian Miles, MD SSI Schaefer, Asia Pacific & Middle East 2 industrial automation asia | August 2010

49 Hazard Control

Law makers are in the process of formulating legislation to manage the use of toxic substances in electronics manufacturing.

By Gary Nevison, head of Legislation, Premier Farnell

New Perspectives with SIMATIC PCS 7 Process Control System Exceeding the Requirements of the Process Automation Market: SIMATIC PCS 7 – more than just a process control system INTERNET

Web Client – Bedienen und Beobachten – Maintenance

Data Monitor

Management Information / Manufacturing Execution System

SAP

SIMATIC IT

Office LAN, Ethernet Security Module

OS / Batch / Route Control / TeleControl Clients SIMATIC PCS 7 Box

OS Single Station

Web Server / OpenPCS 7

Netzwerkdrucker

INTERNET

Maintenance Station Client

Engineering Stationen

Terminalbus, single / redundant OS / Route Control Server

Batch- / ArchivServer

TeleControl OS Server (dediziert oder zweikanalig)

Maintenance Station Server

Industrial Ethernet, single / redundant

SIMATIC ET 200M

StandardAutomatisierungssysteme

SIMATIC PCS 7 AS RTX

Hochverfügbare Automatisierungssysteme

Sicherheitsgerichtete Automatisierungssysteme

SIMATIC ET 200M single / redundant

SIMATIC ET 200M

SIMATIC ET 200M Standard- und F-Baugruppen

Wägesysteme FF-H1

Zone 2

Zone 1 SIMATIC ET 200M

DP / FF Link Ex-I/O, HART

AS-Interface

DP / PA Link

DP / AS-Interface Link Modbus, serielle Kopplung PROFIBUS DP

MTA

SIMATIC ET 200M F-Baugruppen

SIMATIC ET 200iSP

SINAUT ST7 zentrales SINAUT TIM

DP / PA-Link

DP / PA-Link mit redundanten DP / PA-Kopplern

PROFIBUS PA

PROFIBUS PA

PROFIBUS PA

Modem

WAN

FremdRTU

SIMATIC S7-300

FremdRTU

SIMATIC ET 200S PN-CPU

SIMATIC ET 200S PN-CPU

SIMATIC S7-300

SIMATIC S7-300

COx, NOx

SIMATIC S7-400

DP / PA-Link SIMATIC ET 200pro

SIMATIC ET 200iSP HART

SIMATIC ET 200S PROFIBUS PA

Integrated Drives

TCP / IP seriell

WAN

Active Field Splitter

PROFIBUS DP-iS

SIMATIC ET 200S

TCP / IPWAN-Router

Modbus Ex-Bedienterminal

Y-Link

SIMATIC ET 200M mit CP 341

TeleControl zugeordnete Komponenten

Industrial Ethernet, Protokoll IEC 850-5

PROFIBUS DP

PROFIBUS DP

Active Field Distributors

Design and Engineering

PROFIBUS DP

weit verteilte TeleControlAußenstationen

SIMATIC S7-400

SIMATIC S7-400

Operation

Advanced Process Library with extended functionality*

Advanced alarm management

Change management (Version Trail, Change Log, etc.)

Redundant archive management

Concurrent (Multi-user) engineering capability

Extensive industrial security architecture

Full material transport with SIMATIC Route Control

Easy data exchange between auxiliary systems Modern and ergonomic user interface *

New operation modes (Program, Out of Service, Local) * Centralized visualization schemas *

Direct Excel link to real-time and historical data (DataMonitor) *

Cause and Effect safety related programming

Full OPC support

Integrated control of widely distributed systems with TeleControl *

Batch and Route Control fully integrated into the OS

Powerful controllers with scan times as low as 10 ms

Redundancy (controller, I/O module, field/plant buses)

Enhanced trending boasting continuous x-y zoom, multiple trends and auto-scaling *

Advanced Process Control functionality

User-specific alarm filtering *

Bulk engineering functions including CAE/CAD connections

Wide-screen 16:10 and 16:9 resolution support

IO Modules for hazardous areas

Scalable client/server architecture, including a powerful web client

Common hardware platform for Process Safety Drag-and-drop AS-AS communication *

More adaptable CFC function blocks *

Straightforward navigation (Loop-in-alarm, source of interlocking, bypass identification, jump to faceplate) * Automatic signal quality determination *

SIMATIC PCS 7 AS RTX Microbox for economic solutions for labs, pilot plants and process OEMs Engineering Compendium with Engineering best practices *

Maintenance

Central, system-wide visualization, diagnostics and maintenance of all process control components

Condition and plant performance monitoring

System-wide maintenance document management

Predictive maintenance features

Integrated diagnostics with intelligent field devices

Hot swapping of modules during operation

Installation and Commissioning

HART and FF fully integrated into PROFIBUS DP

TÜV SIL 3-certified communication with PROFIsafe

Redundant configuration of PROFIBUS and HART

Sequence of events and time stamping down to 1ms

Fiber-optic switching technology

Checklists for common and relevant engineering tasks for faster, more effective documentation *

Intrinsically safe applications all the way to Ex zone 0 can be handled

by ET 200iSP I/O modules Forcing of connected CFC input parameters *

www.siemens.com/simatic-pcs7

Modernization and Upgrade

Step-wise strategies for modernizing existing systems

Online expandability

Inquiry: admarketing.sg@siemens.com

ENQUIRY NO. 133

contents

z August 2010 IndustrialAutomationAsia August 2010

August 2010

MICA(P) 039/07/2010 | ISSN 0219/5615 | PPS 1561/06/2011 (028597)

ENERGY

50

Case Study: Controlling The Field

www.iaasiaonline.com

Field device management technology is being implemented at Nestle’s renewable diesel plant in Singapore. By Laura Virta, lead engineer, Metso

www.iaasiaonline.com

MICA(P) 039/07/2010 | ISSN 0219/5615 | PPS 1561/06/2011 (028597)

Precise Detection

Sensors With

M2M:

SCADA:

Easy Field Access

Rugged Design IAA Aug2010a.indd 1

Water Management:

Progressing Performance

Cover: Baumer

7/26/10 5:49 PM

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Partnerships

As China’s gargantuan economic engine chugs on, players from all over the world are also climbing onboard.

The tiny city-state of Singapore for one, is encouraging cooperative efforts between the two countries. At the SingaporeJiangsu Innovation Cooperation Conference that was held in Nanjing, Lee Yi Shyan, minister of state for Trade and Industry and Manpower, encouraged high-tech enterprises from both countries to set up R&D centres in each other’s markets – to expand regionally and globally. In line with this trend, STMicroelectronics has announced an R&D partnership with Tsinghua University to jointly work on applications engineering projects.

In the area of energy generation, Invensys has signed a second long-term agreement with China Nuclear Power Engineering to provide safety and distribution control systems for two water reactor units on Hainan island.

With India and China in the lead, Asia Pacific has been making rapid progress in wind power. Frost & Sullivan estimates that wind energy generation in the region has grown from 1.7 GW in 2000 to 41 GW in 2009.

Further south, Australia’s News Ltd – owned by Rupert Murdoch – has selected Cummins Power Generation to supply a turnkey power solution. In the western part of the country, ABB has won an order worth US$26 million from Rio Tinto to raise the capacity and reliability of existing power transmission lines to iron-ore mines.

In the Middle-East, Masdar has partnered with Total and Abengoa Solar to own, build and operate the world’s largest concentrated solar power plant. The plant is expected to produce about 100 MW of clean energy and will displace 175,000 tonnes of CO2 each year.

In both personal and business relationships, choosing a suitable long-term partner requires time and effort. However, as the decision is likely to result in ultimate success or failure, the resources spent would probably be worth the while.

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Bernard Lee, Alex Hsiao, Marina Ohrn Hormoz Kazemzadeh, Chris Smith, Eduardo Ballina Maryanne Steidinger, Oh Tee Lee, Daniel Dossenbach Sarah Jess, Adrian Schwarz, Brian Miles Annalisa Belante, Jonas Berge Laura Virta, Gary Nevison Editorial Consultants

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ENQUIRY NO. 138

Industry News STMicroelectronics and Tsinghua University Announce R&D Partnership

Shenzhen, China: STMicroelectronics and Tsinghua University, Shenzhen Graduate School, have reached a long-term strategic research partnership agreement. This agreement is the second phase of a collaboration that began in 2002 with the setup of a joint Application Specific Integrated Circuit (ASIC) research centre.

The former is to provide the university with digital multimedia and analog chips, expert support and design tools, and jointly cooperate on applications engineering projects assigned by the former to the university. Under the terms of the strategic

partnership, ST will also donate RMB1.0 million (US$150,000) to the graduate school each year for five years, with an overall assessment of research efforts conducted each year.

The graduate school and the Electronic Engineering department of Tsinghua University will staff the long-term partnership with talent, including graduates and technical staff that have know-how for the market in China – such as local standards and technical specifications in various application fields.

China and Singapore To Partner In Technological Innovations Singapore: Lee Yi Shyan, Minister Of State (MOS) for Trade and Industry and Manpower, stressed the importance of joint collaboration in technological innovations to enterprises at the closing ceremony of the Singapore-Jiangsu Innovation Cooperation Conference (SJICC) held in Nanjing.

Mr Lee said: “Science and technology is imperative for economic transformation and restructuring. Technological innovations can help enterprises raise their value propositions and competitiveness, as well as develop new products and markets. I am happy to support this private sector initiative as our research institutes and experts work together to achieve knowledge exchange and transfer towards the advancement of both our business and social communities.”

Both Mr Lee and Jiangsu vice governor Zhang Weiguo spoke at the closing of the conference in their capacities as vice co-chairmen of the Singapore-Jiangsu Cooperation Council (SJCC), which was formed in November 2007.

Khaw Boon Wan, minister for health and Liang Baohua, Jiangsu Party secretary are the co-chairmen. International Enterprise (IE) Singapore is the Singapore secretariat for the council.

Science and technology is one of the six key focus areas supported by the council. At the conference, Mr Lee highlighted that Singapore and Jiangsu should tap on the SJCC to develop capabilities in science and technology together. Three potential ways of partnership include: 8 industrial automation asia | August 2010

• Encouraging institutions of higher learning and research institutes to heighten exchanges and cooperation; • Encouraging high-tech enterprises from both sides to set up R&D centres in each other’s market so as to introduce their products to new markets regionally and globally; • Encouraging high-tech start-ups from both sides to leverage each other’s existing incubators to obtain key resources and services to further develop and expand overseas.

During the closing ceremony at the SJICC, Mr Lee and vice governor Zhang witnessed 10 Memorandum Of Understanding (MOU)/ Letter Of Intent (LOI)/agreement signings between Singapore and Jiangsu companies and institutes in the R&D sector. The Singapore companies/ institutes included the National University of Singapore and Nanyang Technological University.

In addition, Mr Lee and vice governor Zhang unveiled the plaques for the establishment of the Jiangsu-Singapore Technology Transfer Promotion Centre and the JiangsuSingapore Joint Research Centre on Organic/Bio Electronics & Information Displays.

Industry News

Invensys Wins Contract With CNPE In China Hainan, China: Invensys Operations Management has signed a second long-term agreement with China Nuclear Power Engineering (CNPE).

This is to provide safety and distributed control systems and solutions for t w o 6 5 0 M W p re s s u r i s e d w a t e r reactor units under construction on Hainan Island.

Under the terms of the contract, the former will provide its Triconex critical control and Foxboro I/A Series Distributed Control Systems (DCS) for the Changjiang Nuclear Power Plant.

The former addressed the latter’s safety and availability requirements by providing a diverse, scalable distributed control and safety solution.

This includes advanced digital control room design, safety display units, priority logic modules and defencein-depth systems.

Stolthaven Singapore To Establish New Terminal Singapore: Stolthaven Terminals, a division of Stolt-Nielsen, commenced ground breaking for their first phase of the greenfield storage terminal in Jurong Island, Singapore. The start of this project in Tembusu comes after a prolonged delay, which resulted from the economic downturn during the past few years.

Agreements have been made with the Engineering, Procurement, Construction (EPC) contractor, Chiyoda and site preparation is already underway.

The first phase will comprise 61,000 cubic metres of capacity made up of both gas spheres and conventional liquid tanks. The intention is to build out over 300,000 cubic metres in successive phases to support the new chemical manufacturing plants as well as the growth for existing production.

Government Support Drives Momentum for Wind Energy In Asia India: In recent years, the Asia Pacific wind energy market has taken strides forward. Developed nations such as the US and European countries had a strong head start owing to government support, regulations, and the infrastructure to explore the potential of wind energy.

During the course of the decade, emerging economies in Asia Pacific, particularly India and China, have made rapid progress and have expanded wind energy generation from 1.7GW in 2000 to 41GW in 2009, according to Frost & Sullivan.

Encouraging Expansion The growth of the market is due to the geographically favourable location, government support, recognition of potential, emphasis on renewable development, and energy security.

“Asia Pacific accounted for 41 GW capacity in 2009, almost doubling its capacity from 2008,” says financial analyst Sivapriya Ramakrishnan. “Growth in Chinese installations uplifted the global wind energy market.”

Although domestic investment is overshadowing foreign investment, the scope for foreign investment is likely to increase through the course of 2010 as new regulations encourage markets to open up. The Asia Pacific wind energy market was largely immune to the economic downturn, as government-aided institutions and local utilities provided most of the funding for wind energy projects.

Globally, there were some problems due to the economic slowdown; however, the stimulus packages (particularly those of the Chinese and Indian governments) provided a shot of adrenalin for the renewable energy market.

While the prospects for the market look upbeat, there are some challenges in market progression. About 30 percent of the wind energy generated does not reach the grid due to inefficiencies. The existing grid is not equipped to transport renewable energy. Unless the grid is upgraded, the generation of renewable energy can be seriously hampered.

Apart from this, ambiguity regarding legislation such as the Mandatory Renewable Energy Target (MRET), Generation-Based Incentives (GBI) and emissions trading has slowed market momentum. Solar energy is approaching large-scale commercialisation and its attractiveness will eventually overshadow wind energy.

Other Opportunities Offshore potential is large in most parts of Asia Pacific and Australia. However, the cost of developing offshore wind power is 2-3 times higher, creating a roadblock. There have been notable innovations in deepwater floating turbines and shallow-water turbines, and these advancements will make harnessing offshore potential a viable option. India, China, Australia, Vietnam, and Thailand are investing in High-Voltage Direct Current (HVDC) systems to support their increasing power load. HVDC also supports renewables, as it enables transmission over longer distances (remote sites) and connects offshore wind power through efficient underwater cabling and lower power loss.

The development of feasible energy storage technologies can enhance the contribution of electricity generated by wind energy to the grid. Countries such as Japan are highly dependant on the commercialisation of storage technologies to increase the contribution of renewables.

“Wind power capital costs are the lowest in Asia Pacific and it is expected to be reduced by another percent to 30 percent in the next decade,” says Ms Ramakrishnan. “In the event of the cost reduction and grid upgrading efforts, wind energy is expected to grow steadily.”

August 2010 | industrial automation asia 9

Industry News

Vero and MIRDC To Promote Software Solutions In Taiwan

APPOINTMENTS & NOTICES AMT Appoints GM Applied Manufacturing Technologies (AMT), a supplier of factory automation design, engineering and process consulting services has announced the appointment of Andy Jones as the company’s automotive GM. Mr Jones will be responsible for all aspects of the company’s automotive business unit including engineering operations and sales.

Belden Appoints VP Sales & Marketing Richard Youhill, operations director, Vero and Huang Chi-Chuan, chairman of the board of directors, MIRDC

Taipei, Taiwan: Vero Software, a provider of CAD/CAM/CAE solutions for the tooling industry, has entered into an agreement with the Metal Industries Research and Development Centre (MIRDC) of Taiwan. This is to link the former’s CAD and CAM applications with the latter’s software solutions and jointly promote these solutions to the mould

and die makers of Taiwan and China.

Under the agreement, the latter will link its ERP solutions to the former’s VISI die design and manufacturing applications. The latter will also promote and train potential and existing customers on the use and benefits of the software to further their capabilities in advanced mould and die applications.

CNOOC Closes Joint Venture Deal With BEH Hong Kong: CNOOC and Bridas Energy Holdings (BEH) have completed the formation of a 50/50 percent joint venture in Bridas Corp. CNOOC paid approximately US$3.1 billion.

Chairman and CEO of CNOOC, Fu Chengyu commented: “This transaction with BEH is of significance in our

globalisation plan.”

Chairman and CEO of BEH, Carlos Bulgheroni said: “With the Joint Venture, Bridas has made another step forward in the process started with Amoco Corporation that resulted in the creation of Pan American Energy.”

Belden Announces Network Design Seminar Orlando, USA: Belden will present the Hirschmann 2010 Mission Critical Network Design Seminar from September 19-22, 2010 at the Renaissance Orlando at SeaWorld Hotel in Orlando, USA. The seminar is focused on industrial ethernet networking. It is intended for system integrators; network design engineers with Original Equipment 10 industrial automation asia | August 2010

Manufacturers (OEMs) or Engineering Procurement and Construction (EPC) firms; and anyone involved with the design, implementation and maintenance of mission critical ethernet networks. During the seminar, attendees will learn how to reduce costs and installation time by implementing a resilient network design.

Belden has appointed Keith Mauck as VP Sales and Marketing – Infrastructure Business Group Asia Pacific excluding China (APxC). In this role, he is responsible for driving growth in the APxC region.

Country Director In Indonesia The company has also appointed Holden Chen to country director in Indonesia. Mr Chen will drive sales growth in Indonesia and strengthen pre-sales demand-creation capability. He is based in the Singapore office.

His assignment is supportive of the company’s two strategic priorities: talent development and emerging markets.

Siemens Introduces Executive VP Siemens has appointed Raimund Klein, executive VP of Siemens Singapore, Industry Automation and Drive Technologies. Mr Klein is responsible as a division lead for the ASEAN cluster and for Singapore operations. He is charting the course for a working program for the next 12 months, called ‘Operational Excellence 2010’ that focuses on the five priority areas – Performance and Portfolio, Innovation, People Excellence, building a strong leadership culture and ensuring compliance in business operations.

Industry News

Honeywell Introduces Enhancements For Wireless Networks Arizona, USA: Honeywell has announced enhancements to its OneWireless offering that will give industrial facilities more options to tailor wireless networks to fit their needs.

OneWireless R200, which is now fully compliant with the ISA100.11a standard, will allow plants to design a wireless network with different types of wireless coverage.

Depending upon application requirements, plants can now design networks that provide either wireless coverage for field instruments only, or coverage for both field instruments and Wi-Fi devices. Additionally, features have

been introduced that can reduce the installation and maintenance costs of wireless field instrument networks by up to 50 percent. These features simplify how industrial facilities install and expand their wireless networks and help to maximise field transmitter battery life.

“Many process manufacturers are looking for smaller, tactical wireless networks for specific field instruments, but they also want something that will expand to support more comprehensive, plant-wide wireless solutions,” said Norm Gilsdorf, president of Honeywell Process Solutions.

Semiconductor Equipment Manufacturer Selects Crossing Automation California, USA: Crossing Automation has announced that its Spartan Equipment Front End Module (EFEM) has been selected by a leading manufacturer of lithography and metrology equipment for the latter’s second-generation metrology tool.

The EFEM was selected because of the former’s ability to customise the tool to meet the customer’s specific requirements, the ease of software integration with its metrology platform as well as the former’s ability to provide its ExpressSolutions engineering support to reduce time to market.

Metso Holds Foundation Stone Laying Ceremony In Finland Helsinki, Finland: The foundation stone for Metso’s engineered valves factory has been laid in Vantaa, Finland. The Finnish production of the company’s engineered valves and personnel in automation and power generation in the Helsinki region – 800 people in all – will move to Vantaa at the beginning of 2011.

Pasi Laine, president, Energy and Environmental Technology, says that Finland Metso develops and manufactures engineered valves intended for applications in the oil and gas industries and in power generation.

The facility is a continuation in the line of investment decisions to develop the company’s services globally. The builder of the Vantaa factory is Sponda, a real estate investment company. Metso will lease about 23,000 square metres of production facilities under a long-term agreement with Sponda. The latter is also leasing to the former, about 12,000 square metres of office and warehouse space.

DPI To Lead In Mobile Network Test & Optimisation New York, USA: Deep Packet Inspection (DPI) will lead the field of mobile network test and optimization solutions by 2013 and is expected to generate equipment revenues of US$1.3 billion in 2015. Other approaches include client applications on handsets, radio test equipment and radio probes, routing/transport equipment, operation support software, and network-based offloading, according to ABI Research.

Mobile operators’ network capacity woes have garnered much public attention, and according to mobile networks practice director Aditya Kaul, they will get worse before they get better. “Brute force won’t solve this problem,” he says. “If you double the number of smartphone users, you can’t just spend US$10 billion to double the capacity of your infrastructure.”

The answer lies in making existing networks more efficient. A growing arsenal of equipment and techniques from a variety of vendors aim to optimise different parts of the network and base station.

“These solutions are relatively inexpensive and cost-effective,” notes Mr Kaul. Each operator may have a different set of needs. AT&T, for example, has two problems: too much data traffic (eg: iPhone video) and also too much signalling traffic – the mechanics of running the network.

So, according to Mr Kaul, they would need DPI, routing/transport optimisation, and maybe some UE client software installed on the smartphone. Other operators may have different challenges.

To meet those needs, solutions are arriving from a variety of vendors including Tektronix Communications, Anritsu, Agilent, EXFO, Astellia, and a large ‘other’ group of vendors that collectively command a 28 percent share of the market. It is from that ‘other’ group that much of this segment’s innovation will flow. Says Mr Kaul: “This is a wide-open market. It’s anybody’s game at the moment. There are a lot of small companies with new ideas and a lot of ‘crosstalk’ between them.”

August 2010 | industrial automation asia 11

Industry News

Canada Post Selects Intermec To Enhance Delivery Operations Washington, USA: Intermec has announced that Canada Post, the official postal service of Canada, has selected the former’s CN50.

This is to equip more than 8,000 footbased letter carriers to meet the delivery operations requirements to provide timely delivery information to customers for all traceable items.

The CN50 is part of the Canada Post Personal Data Terminal (PDT) solution that is being used to migrate away from paperbased delivery scan recording processes.

In order to ensure real-time upload of scanned data, it will be necessary to eventually equip all letter carriers with a

PDT capable of transmitting information through a high-speed reliable cellular network.

“As part of Canada Post’s Postal Transformation initiative, the PDTs will be leveraged to deliver real-time parcel visibility and improve letter carrier productivity, delivering sustainable ROI,” said Peter Duncan, director Engineering Product Tracking Processes and Systems of Canada Post.

The PDT solution enhancement is part of a transformational Canada Post program to modernise its postal network end to end.

Adept Technology Announces Acquisition Of MobileRobots Pleasanton, USA: Adept Technology has entered into an agreement to acquire privately held MobileRobots, a provider of autonomous robot and Automated Guided Vehicle (AGV) technologies. Based in New Hampshire, the latter positions the former to deliver productivity gains

in unstructured environments, many of which reside beyond traditional ro b o t a p p l i c a t i o n s . E q u i p p i n g Adept’s global sales channels with autonomous robots and associated technologies will enable the company to address the needs of the production logistics markets.

Missler Launches Web Sites

Alstom & Schneider Electric Finalise Acquisition Of Areva Businesses France: Alstom and Schneider Electric have proceeded with the closing of the acquisition of Areva T&D’s transmission and distribution businesses. This was after obtaining the approvals of the relevant competition authorities and the French Commission des Participations et des Transferts (CPT).

A consortium agreement was signed by the two partners in November 2009 for the purpose of this joint acquisition. The price paid for Areva T&D’s shares amounted to €2.29 billion (US$2.85 billion). The net financial debt of Areva T&D was about €0.89 billion as of December 31, 2009.

The consortium agreement sets out the transfer of the Transmission business (about two thirds of the total) to Alstom and of the Distribution business (about one third) to Schneider Electric, as well as the ways under which they will be managed.

The agreement allows both acquirers to immediately assume separate operational responsibility of each of these businesses.

The two companies will also develop cooperation between the Transmission and Distribution businesses, via commercial and license agreements. R&D agreements will be put in place for the development of innovating technologies, to the benefit of both companies.

Isothermal Technology Celebrates 30-Year Anniversary Evry, France: Missler Software has revamped its TopSolid web sites.

Visitors can now find out about the range of CAD/CAM solutions on offer, customer references, resellers and product videos in a more user-friendly interface.

12 industrial automation asia | August 2010

The English and French web sites have been launched and the German site will be available before the summer vacation.

The look for the web sites is in line with the company’s graphical identity, which was launched last year.

U K : I s o t h e r m a l Te c h n o l o g y i s celebrating its 30th year in business.

The company was founded in 1980

by John Tavener as an instrumentation company supplying thermocouple reference instruments to the nuclear industry. It currently employs 48 people with all manufacturing in the UK.

Industry News

Brano Hudak, Slovakia

News Ltd Appoints Cummins For Turnkey Power Solution

Sydney, Australia: Australia-based newspaper publisher, News Ltd, has chosen Cummins Power Generation to supply the former’s Sydney headquarters with a turnkey power solution.

The publisher is owned by Rupert Murdoch and accounts for around 70 percent of Australia’s circulation; it electronically produces principal dailies such as The Australian (Australia’s only national daily broadsheet), The Daily

Telegraph and The Sunday Telegraph.

There was a need to develop an emergency power system to ensure the company’s data centre – which operates round the clock worldwide – is kept running and producing its publications.

The power package comprises of three C350 D5 generator sets complete with PowerCommand 3100 digital paralleling equipment and a DMC1000 digital master control system.

ABB Selected

By Rio Tinto In Australia WA, Australia: ABB has won an order worth US$26 million from Rio Tinto to increase the capacity and reliability of existing transmission lines supplying power to the latter’s iron-ore mining facilities in Western Australia.

As part of the turnkey solution, the former will design, supply, install and commission a Flexible Alternating C u r r e n t Tr a n s m i s s i o n S y s t e m s (FACTS) system including a Static Var Compensator (SVC), to optimise the transmission network in the region. The solution also includes the extension of an existing 220 kV substation and supply of capacitor banks.

“This solution will boost power capacity and improve grid stability. It will also help reduce environmental impact since it is designed to enhance the supply of electricity through existing transmission lines,” said Martin Gross, head of ABB’s Grid Systems business, within the Power Systems division.

The latter has committed significant investment to upgrade the port, rail, power, and mine assets in the Pilbara region. This upgrade protects the power supply to the company’s iron ore mines in the area. It is in addition to several substations ranging from 33 kV to 220 kV that the former has supplied to the latter.

World’s Largest Concentrated Solar Power Plant Abu Dhabi: Masdar has appointed the bidding consortium of Total and Abengoa Solar as a partner to own, build and operate Shams 1, the world’s largest concentrated solar power plant and the first of its kind in the Middle East.

One of Masdar’s flagship projects, Shams 1 will directly contribute towards Abu Dhabi’s target of achieving seven percent renewable energy power generation capacity by the year 2020.

The joint venture between Masdar (60 percent), Total (20 percent) and

Abengoa Solar (20 percent) will develop, build, operate and maintain the plant which will be located in Madinat Zayed, approximately 120 km southwest of Abu Dhabi in the United Arab Emirates (UAE).

Shams 1 will be the largest concentrated solar power plant in the world, extending over an area of 2.5 square kilometres, with a capacity of approximately 100 MW and a solar field consisting of 768 parabolic trough collectors to be supplied by Abengoa

Solar. Construction is set to begin during Q3 2010 and is expected to take approximately two years.

Shams 1 is registered as a project under the United Nations’ Clean Development Mechanism (CDM) and is eligible for carbon credits. It is the first CSP plant registered under the CDM and the second project registered for Masdar. The plant will displace approximately 175,000 tonnes of CO2 per year, equivalent to planting 1.5 million trees or removing 15,000 cars from Abu Dhabi’s roads.

August 2010 | industrial automation asia 13

Newsdesk

CANopen:

Standardised Embedded

Machine Control Network The man in Brown’s print shop in Oldham, England, loads the paper coil into the CutStar CAN machine. He does not know that Heidelberger (an offset printing machine manufacturer) interconnects the down-stream machine via CANopen to the Speedmaster CD 74-12+LX printing machine. The CANopen network is embedded, meaning that the operator of the machinery does not need to configure the communication system.

Another scene: The machine fills 25 coffee pads per second. In an hour the machine produces up to 1,500 coffee pads. The servo axes within the machine are linked via a CANopen network that also connects several I/O modules and the human machine interface to the central Programmable Logic Controller (PLC).

CANopen is an embedded control network – not only in printing and packaging machines.

In many other machine classes, this network technology is used for communication between controller and drives.

It was originally developed within a European research project chaired by Bosch. The specifications were handed over to the nonprofit CAN in Automation (CiA) international users’ and manufacturers’ group for further 14 industrial automation asia | August May 2009 2010

All peripheral units are networked with the main press unit via CANopen

developments and maintenance.

The 60-pages of specification have been extended by additional communication ser vices and protocols as well as many generic and application-specific profiles.

Today the entire family of specifications comprises more than 6,000 pages. The device developer selects the required communication functions and implements them in the product’s interface. Flexibility regarding functionality and scalability are the main benefits of the technology.

Nevertheless, the definitions

given in the CANopen device and application profiles lead to interoperable and easy-tointegrate devices. Embedded machine control networks require standardised process data, configuration parameter, and diagnostic information. These are transmitted by means of Process Data Objects (PDOs), Service Data Objects (SDOs), and EMCY messages (emergency object).

CANopen also provides a standardised network management by means of the Network Management (NMT)

machines by Heidelberger ensure production speed, short makeready times, and little waste.

CANopen helps to achieve this by its flexibility. Flexibility is also required for the embedded network in the FlexPose laser ablation system by Lüscher.

The British branch of the company has selected CANopen as

the embedded network for linking the servo drives in order to easy the customisation of the machine.

The machine design reduced the amount of devices within the laser ablation system by 10 percent. In addition, the network eliminated the expensive cabling.

ENQUIRY NO. 5101

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message and the Hear tbeat message. All these communication services are mapped to one or more Controller Area Network (CAN) messages. CAN is the data link layer protocol used in CANopen networks.

CAN was originally developed as in-vehicle network for passenger cars. About two billion CAN controller chips have been sold since their introduction in 1989.

The prices for micro-controllers with on-chip CAN modules are reasonable. This is also true for the transceiver chips.

CANopen as application layer protocol may be implemented by anybody without any license fees.

For those who do not like to reinvent the wheel, several software houses provide CANopen protocol stacks. Another advantage of a standardised network technology is the availability of tools from dif ferent manufacturers for device development, system configuration, and diagnostics.

The embedded machine control networks that are based on CANopen, connect PLCs and other controllers to I/O modules, dedicated sensors, electrical and hydraulic drives as well as human machine interfaces. Most of these devices are compliant to a standardised profile (CiA 401 for I/O modules, CiA 402 for drives, CiA 406 for encoders, etc). In addition, the system designer has to specify the physical layer in detail.

The specification just specifies the bit-timing and maximum network length for different bit-rates. The cable and the connector selection may depend on the application requirements as well as the network topology.

The CANopen standard topology is a bus-line with stub cables.

If repeaters are used, other topologies such a tree and star lines are possible.

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August May 2009 2010 | industrial automation asia 15

Asia

Safety Over EtherCAT Now An International Standard Together with the IEC 67184-3 standard, the Safety-over-EtherCAT Protocol has been accepted by the 27 national IEC committees.

Achieving this international standard is an important milestone for the EtherCAT Technology Group (ETG). It will further leverage the acceptance and uniform usage of EtherCAT technology within the automation world.

The protocol is referred to as Functional Safety Communication Profile (FSCP) 12 in IEC 61784-3. This standard defines the fundamental requirements of a communication system in terms of safety relevant data transmission. In order to do so, it also defines potential errors whose occurrences have to be assumed and describes possible recognition and corrective measures. All requirements are met safely by the Safety-over-EtherCAT Protocol.

16 industrial automation asia | August 2010

The protocol is ideal for applications up to the Safety Integrity Level SIL3 according to IEC 61508. Safety communication and standard communication use a single bus system.

Usage of the protocol however is not limited to EtherCAT. By employing the ‘black channel’ approach it is ensured that the safety quality is independent of the communication channel: EtherCAT, Ethernet, other fieldbus systems, underlying subbus-systems and even wireless communication links are allowed.

This is confirmed by the certification of the notifying body TÜV SÜD and is used in practice: S a f e t y - o v e r - E t h e r C AT d a t a containers are routed via standard controllers and even gateways to neighbouring systems where they

are interpreted in a safe manner – one safety domain can successfully span the entire installation.

“Safety-over-EtherCAT is simple to implement, bus independent and open,” says Dr Guido Beckmann, who is in charge of the Safety-overEtherCAT Technology within the ETG. “The acknowledgement of this safety protocol as an international standard is another logical step towards the proliferation of EtherCAT technology. It provides additional reassurance to both device manufacturers and end users who can depend on a stable and globally accepted technology.”

The publication of the international standard IEC 61784-3 Ed.2 is expected soon.

ENQUIRY NO. 5102

ENQUIRY NO. 146

Trine University and SAIT Polytechnic

Complete FCTP Educational Certification Process

The Fieldbus Foundation has announced that Trine University, Angola, Indiana; and SAIT Polytechnic, Calgary, Alberta, Canada, have successfully completed the cer tification process under the Foundation Cer tified Training Program (FCTP). This program establishes uniform standards for fieldbus educational curriculum around the world and defines acceptable levels of learning for students of the foundation’s technology.

It ensures the availability of thorough, comprehensive and accredited training to the process automation marketplace.

According to Fieldbus Foundation Marketing Manager Bill Tatum, the FCTP was established to ensure instructors delivering fieldbus educational courses are skilled, knowledgeable and technically competent. Through c e r t i f i c a t i o n , t h e p ro g r a m demonstrates to prospective end user students that fieldbus training centres, and their instructors, have been thoroughly evaluated based on strict criteria, and have the necessary qualifications to provide training.

The procedures that educational institutions must follow in order to gain certified foundation training site status, together with certified course instructors and certified curriculum, are rigorous. For example, certified training centres are required to maintain multiple fieldbus hosts and devices onsite in order to demonstrate competence with fieldbus technology.

18 industrial automation asia | August 2010

They must also demonstrate to auditors that their course material adheres to set instructional standards covering fieldbus segment limits; device replacements; commands, icons, menus and screen designs of different software packages; and communication, scheduling and function block assignments enabling configuration.

In addition, certified instructors are audited to see if they have achieved specified Fieldbus Foundation training goals.

Instructors must demonstrate expertise in areas such as HumanMachine Interface (HMI) tools, fieldbus troubleshooting, simple device configuration, and device deployment and functionality across a fieldbus network.

The FCTP currently offers three levels of certification, and others may be added in the future.

The current certifications include Foundation Certified Professional, Foundation Certified Support Specialist, and Foundation Certified Technical Specialist.

Educational facilities that complete the multi-stage FCTP certification process can issue certificates showing the Fieldbus F o u n d a t i o n a c c re d i t s t h e i r courses.

Around the world, institutions currently certified under the FCTP program include: Fieldbus Centre at Lee College, USA; Trine University, United States; SAIT Polytechnic, Canada; and STC Brielle, The Netherlands. Other training centers participating in the program include: University

of Miskolc, Hungary; Waseda University, Japan; and King Mongkut’s Institute of Technology, Thailand.

The foundation and SAIT Polytechnic signed a partnership agreement to establish a training facility on the SAIT campus in Calgary. SAIT offers Foundation fieldbus Certified Professional – a comprehensive five-day training p ro g r a m c o m p r i s e d o f t h e following courses: Foundation fieldbus Essentials, Foundation f i e l d b u s D i s c o v e r y, a n d Foundation fieldbus Practices.

Upon successful completion of this course, participants receive Foundation Certified Professional certification.

SAIT has upgraded its foundation fieldbus lab to incorporate Foundation High Speed Ethernet (HSE) technology.

The new system interoperates fieldbus instruments from over a dozen different manufacturers.

This system, used for the laboratories, along with Honeywell Experion, Yokogawa CENTUM, Smar System302 a n d E m e r s o n D e l t a V, g i v e s trainees exposure to a diverse and comprehensive fieldbus experience. SAIT’s fieldbus lab facilities provide each trainee with their own training station and include four foundation f i e l d b u s d e v i c e s f ro m f o u r differing manufacturers. Over 2 0 d i f f e re n t m a n u f a c t u re r s o f f i e l d b u s e q u i p m e n t a re represented in the lab.

ENQUIRY NO. 5103

Industry Updates

Profinet:

Industrial Ethernet Based Fieldbus Profibus International has developed a standard out of the experience gained from the development of Profibus to adapt industrial ethernet to the special requirements of industry. The result is Profinet, an extensive standard for open, manufacturer-neutral communication via industrial ethernet. The standard meets the requirements for using ethernet at all levels and in all applications of automation. This makes Profinet flexible, reliable and robust in an industrial environment.

Protection Of Investment

Numerous field devices from different vendors as well as drive products and network components ie: switches, are available with Profinet functionality. This interface provides on almost every device, a two-port switch on board to build up a line structure.

The integration of existing fieldbus systems and protection of investment is an essential part of Profinet.

The device model on the standard is based on the Profibus model, which means that the I/O modules of the existing peripheral devices can still be used.

There are controllers available like Simatic S7 CPUs from Siemens which have both an ethernet and a Profibus interface. Existing systems can therefore be easily integrated to the Profinet environment, without the operators having to write new user programs or change complete Profibus devices.

Another possibility of integration is the proxy technology – for example, the IE/PB Link PN IO of Simatic Net – which acts as a representative of the subordinate Profibus devices. This link is also available with a wireless LAN interface, and provides innovative possibilities to integrate Profibus with wireless technology into Profinet solutions.

C

Ethernet In Real-Time With Profinet

The wide bandwidth allows the use of ethernet in automation. The cyclic IO communication standard TCP/IP and IT protocols can be used at the same time. Profinet IO can be used with a reaction time of 1ms cyclic communication between the Profinet IO Controller and IO Devices. This mechanism works with standard switches. Cyclic communication is based on the OSI/ISO layer model on layer 2. This allows a fast reaction time on the ethernet networks.

Profinet also provides a solution for high deterministic and fast motion control tasks. Isochrones Real-Time (IRT), is used for fast automation tasks with a cyclic communication of 250µs and a jitter <1µs. In this case the network devices need an Application-Specific Integrated Circuit (ASIC) to guarantee the timing.

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ENQUIRY NO. 5104

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Profinet is using the advantages of ethernet technology so that it can be used for tree, ring, and start network structures with either optical or electrical networks medium as well as for wireless. With industrial wireless LAN, Automated Guided Vehicles (AGVs) or mobile operating and maintenance devices can be easily integrated into the automation landscape even with safety technology.

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ENQUIRY NO. 151

Applications With Industrial Wireless LAN Solution

August 2010 | industrial automation asia 19

issues & insights

A

search for products on one of China’s top B2B websites using the key words GPS and GPRS will yield a number of matches – more than 200 pages in total. So it appears that there is no need to introduce yet another Machine-To-Machine (M2M) hardware design into the marketplace.

However, it appears that there is still demand from the market, to be able to measure temperature on refrigerated trailers and report vehicle position reliably back to a centralised server.

At least 2-3 hardware vendors already have a hardware product that meets the requirements, and the software integration with all of them has already been done.

However, there is one additional cr iter ion t hat ne e ds to b e reconsidered – the price of the hardware.

20 industrial automation asia | August 2010

M2M:

Rugged Design Demanding technology that can operate reliably in harsh environments, with an affordable price tag.

By Bernard Lee, MD, Procuro Asia Pacific

Cost Of Reliability Standard GPS hardware for vehicle tracking can be bought in bulk for around US$100. The specialised industrial grade M2M units that are designed for refrigerated transport cost between US$1,000 and US$2,000 per unit – a price that may not be affordable to many.

The question to ask is what

needs to be done, and more importantly, what the associated cost is, to achieve reliability. At first glance, adding temperature monitoring to a standard GPS hardware should not be a difficult task, and the US$100 units have typically already been working reliably in other applications.

Theoretically, they should work

Environmental Protection The number one killer of equipment operating under f luctuating temperatures is condensation.

It is one thing to be operating under humid conditions, but it is an entirely different thing if condensation actually occurs on the electronic components.

Condensation occurs under temperature fluctuations because cold air holds less water vapour than hot air. So, when a cold object is exposed to room temperature, especially where air is continuously circulating, condensation rapidly occurs even though the environment may not be extremely humid.

One of the easiest ways to protect a piece of electronics from condensation is to seal it in an environment-proof enclosure. If there is no air circulation and no

leakage, there will be minimal and negligible condensation inside the enclosure even during large temperature fluctuations.

Env ironment-proofing the enclosure involves two main parts – the enclosure itself, and the electrical connectors, both work ing ha nd - in - ha nd.

Environment-proof connectors

are expensive. The fewer the number of connectors needed, the less expensive the final product will be.

Many of the lower cost units in the market aim to provide as many connections and features as possible. If the same features and flexibility are to be implemented with an environment-proof rating,

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just as well and allow savings to be made if installed into refrigerated trailers. However, this is not necessarily the case.

Most equipment is specified to work under certain temperature and humidity ranges. Hardware that works with refrigerated or chilled trailers are presented with a simple but unique challenge. The hardware needs to be operating under extended temperature ranges. Equipment that is installed in refrigerated trailers need to function reliably when temperature fluctuates between extremities.

For example, the common specification for frozen meat transportation is -18oC, and that for ice cream is -25oC. In the meantime, on a hot summer day when a trailer is parked under the sun, temperatures inside the cab can go as high as 65oC. There appears to be market demand for technolog y that is reliable, yet not a lot more expensive. A need exists, and a device has been designed to fulfill this need.

August 2010 | industrial automation asia 21

issues & insights

the cost of the resulting product is likely to be expensive.

Quest For Simplicity In order to minimise the openings on the enclosure to maintain the environment-proof rating, an attempt has been made to put as much inside the enclosure as possible. The following items have been evaluated to determine what can be put inside the enclosure, what w i l l re qu i re e x te r na l connectors, and what can be eliminated.

• GPRS antenna • SIM card socket • GPS antenna • Backup battery • Sensors • Power connector • Configuration cable • Diagnostics display The GPRS and GPS antennas can safely go inside the box. If the enclosure is robust and environment proof, it can be installed outside the refrigerated trailer with good reception. Just like modern cell phones – no more external antennas, and less items to break.

The SIM ca rd socket a nd backup battery can also be put inside, as it is generally acceptable

When a cold object is exposed to room temperature, especially where air is continuously circulating, condensation rapidly occurs even though the environment may not be so humid.

22 industrial automation asia | August 2010

to remove a few screws to replace a SIM card or a backup battery.

The diagnostic display needs to be eliminated, because it will make the environment-proof enclosure more expensive to engineer and produce.

The inspiration to eliminate the diagnostic display in return for lower manufacturing cost is inspired by the fact that some of the world’s most successful consumer electronics products do not have flashing LEDs that show their operating status.

The theory is that if a product is simple and reliable enough, users will get used to not having diagnostic displays, especially if there is an alternative way of viewing the device’s functioning status online. In the case of M2M products, the primary purpose is to gather operational status information to be displayed centrally, so relaying of operational status would just be a tagged-on additional feature.

For te mp eratu re , do or and cargo sensors, there are compelling reasons to go wireless.

Going for wireless sensors does increase the overall cost of the product. However, it adds three more advantages to the product: simplicity, ease of support and reliability.

Tough Reliability The main justification for adding the extra cost for wireless sensors will be reliability. A typical wired temperature monitoring installation involves putting the main unit in the driving cabin, and then installing a wired sensor through a hole at the back of the truck and another hole through the insulation layer of the refrigerated trailer.

First, to support the extended temperature ranges, standard PVC cables cannot be used as they become brittle under low temperatures. If the insulation breaks, accuracy will be affected – or worse, the system could stop functioning.

Silicon or low temperature resistant cables should be used for wiring under low temperatures.

However, they are softer and are more susceptible to damage outside the refrigerated trailer. To perform a wired temperature sensor installation properly, installation costs and efforts will tend to be higher. Hence, business owners are often placed under the temptation of making compromises. If best practices are not followed during installation, reliability is likely to be the first victim.

The use of wireless sensors, shift engineering decision making from the end user to the product designer. For example, a high powered, low speed 802.15.4 wireless module is preferable over Wi-Fi, as it performs better under suboptimal signal conditions.

There is no wiring involved in installation.

Batter y powered sensors mean that a power source is not required. The only maintenance that is needed is to replace the batteries once every year or two.

As for the base unit – when the GPS, SIM card and all wireless antennas inside the enclosure have been configured, the only wired connection to the box will be the power leads. This reduces the

Tolerating Abuse W h i le mou nte d on mov i n g trucks, vibration and shock to the equipment will be inevitable.

Stress and fatigue caused by this operating condition needs to be taken into consideration.

To re duce st re ss to t he minimum, all components with greater mass and inertia should be removed from the Printed Circuit Boards (PCB). In this case, the batteries are the main items of concern. Therefore, the enclosure has a battery holder built-in, which is completely isolated from the PCB, wired via soldered leads with no mechanical connection.

The PCB is mounted onto the enclosure base through silicon sho c k ab sorbi n g bu sh i n gs.

Sharp impacts to the enclosure will be significantly buffered.

Next, the external International Protection (IP) rated connectors are not directly soldered to the PCB. Lead wires are used for soldered connections between the connectors and PCB. That way, impact to the external connectors will not be directly transmitted to the PCB. Besides the IP rated connectors, the material for the enclosure is also a cost item that should not be compromised. Fiberglass-reinforced nylon is the material of choice. It withstands extreme temperatures and is shatterproof under both hot and cold environments. Fiberglassreinforced nylon however is expensive.

Reg ula r pla stic materia ls might withstand low and high temperatures, but they become brittle and are not shatter-proof under low temperatures. Should production costs need to be lowered further, alternatives like Engineering Polypropylene (EPP)

resin â&#x20AC;&#x201C; would also be a good choice.

EPP is variant of Polypropylene (PP) that takes on the basic characteristics of PP but has better mechanical properties especially under low temperatures. Â Also, even though the casing is sealed, the PCB still needs to be resistant to corrosion. If the enclosure is opened and then sealed

in a humid environment while it is still cold, condensation will still occur.

To overcome this, a condensation sensor is first placed on the PCB. A n a ler t w il l b e se nt i f condensation occurs inside the sensor box after battery replacement. Neither sockets nor jumpers are used on the design of the box. When corrosion occurs,

ENQUIRY NO. 149

chance of introducing a weakest link (in terms of reliability) from not following best practices during the installation process.

August 2010 | industrial automation asiaâ&#x20AC;&#x192; 23

issues & insights

While mounted on moving trucks, vibration and shock to the equipment will be inevitable.

the first to be affected will be the sockets and the connectors. If all components are soldered, minor corrosion will occur on the solder surface, but will not cause permanent damage.

The external IP rated connectors are also designed such that while not in use, a cap will be twisted on to maintain the overall environmentproof rating. The cap is attached to the socket, so that it will not be lost when a connector is present and the cap is not in use.

As for the circuit design, the piece that can make the most difference to withstand abuse is the power supply. Especially when placed inside a sealed enclosure with a material that does not conduct heat, the power supply needs to be efficient. Moreover, trucks can be equipped with 12V or 24V batteries.

The power supply needs to be stable under a range of supply voltages, with reverse polarity protection. The power supply module that meets all of these requirements resulted in being one of the most expensive components on the PCB. Cold Operation There are two more considerations w i t h o p e r a t i n g u n d e r l ow temperature: the battery and 24 industrial automation asia | August 2010

coefficient of thermal expansion.

To date, there is no rechargeable battery solution that will work reliably in the long term under extremely low temperatures. A lithium thionyl chloride cell works best under low temperatures – up to -55˚C where it still retains around 50 percent of its rated capacity.

Lithium iron disulfide batteries also have good low temperature operating characteristics, and a re com monly ava ilable a s replacements to standard alkaline AA batteries. They are also less expensive than lithium thionyl chloride, and are recommended for the wireless sensor units. If the

sensor unit is operating under a chilled (0-4˚C) instead of a frozen environment, standard alkaline AA cells can be used.

To c o m p e n s a te f o r t h e differences among coefficients of thermal expansion across various components, components of typical or smaller sizes are selected, and the selection criteria is that they are lead compliant – that the connecting leads will yield to absorb the stress from thermal expansion.

A piece of equipment is only reliable if the firmware and its associated software are bug free.

Prior to the availability of smart phones, regular cell phones did not have to be rebooted. By the same token, if work done in the firmware can be minimised and if most of the functionality is shifted onto a centralised server instead, any feature corrections and enhancements can be performed on the server side without the need to change the hardware or firmware.

This is the M2M equivalent of the Thin Client or Web-based applications concept – do the heavy lifting on the server side, and any device with a standard browser will be good enough to get the job done.

ENQUIRY NO. 5201

Truth About Water Damage PCBs are often washed with water before they are assembled and tested. Assuming that a cell phone has been exposed to a coffee spill, a good chance of saving the cell phone is to remove the battery immediately, take it apart and wash the PCB (not the LCD) thoroughly with water – preferably distilled – and then dry it out as quickly and as thoroughly as possible.

Water itself is not detrimental to electronics. It is the combination of impure water, or electrolytes, combined with electricity, or electric potential, which destroys electronics components through electrolysis. So, slight condensation under a sealed environment is not very damaging to electronic equipment, as it is primarily distilled water with minimal electrolytes.

When condensation comes from circulating air, it is more damaging because contaminants from the atmosphere will be continuously brought to the condensation, forming an electrolyte that will rapidly interfere with and then damage the electronics under operation.

ENQUIRY NO. 5202

ENQUIRY NO. 126

control point

Progressing

Integrated approach for real-time operations in solutions for water and wastewater

Water Management:

Performance

Improving engineering efficiency and optimising energy costs while expanding sustainable water management systems.

By Chris Smith, director, SCADA Business; Eduardo Ballina, Global Industry Solutions – Water and Wastewater; Maryanne Steidinger, director, Advanced Applications Product Marketing, Invensys Operations Management

26 industrial automation asia | August 2010

A

t the United Nations Millennium Summit in 2000, 189 world leaders agreed to meet the Millennium Development Goals (MDGs): End poverty by 2015. The UN millennium goal number seven, ‘Ensure Environmental Sustainability,’ targets water, forest, and carbon usage in terms of sustainable impact to the environment and quality of life for populations in developing countries.

The Challenge To Utilities In response to these goals, water utilities require more efficient methods of engineering, optimisation of energy supply, and contextualised compliance monitoring as they seek to expand the volume and

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As a sidenote, virtual teams become important in geographically spread, multi-site systems.

Continuous improvements in water reclamation and desalination technology have fostered an

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ENQUIRY NO. 097

availability of water to the general population at an affordable price.

How can engineers create and reticulate clean and affordable water and wastewater services in developing countries using standard technologies? How can the cost equation between energy and water quality inspired by the use of energy-hungry reclaiming and desalination technologies be managed? What intelligent infrastructure is being provided to allow automation vendors to contribute various forms of data in real-time to multi-user operations decision-making?

By the time engineers are managing multiple plants, it is no longer possible to efficiently handle design control and rollout using procedural and listoriented engineering tables. Systems engineering savings of 10:1 to 100:1 can be achieved through the use of online template object-oriented systems.

The benefit of using object-oriented methodology increases in multi-plant systems.

One of the key benefits in encapsulating design, parameterisation, and visualisation in an object methodology, is the easy transfer of knowledge and understanding from year to year, as well as from the older to younger generations of systems engineers.

More recent advances provide design, simulation, checkout, and deployment using one engineering environment, and allow cloning and consistent extension of plant models by lead and contract engineers with minimal errors and design interaction. If the fundamental model of the plant can be described in terms of functionality and data structure, and combined with appropriate visualisation techniques, it may then be extendable and reusable without degradation.

August 2010 | industrial automation asia 27

control point

Typical architecture using object-oriented design

increased ability to produce clean water. However, even with these improvements, water processing operations continue to be energy intensive.

Optimisation of the energy cost equation includes the energy supply tariff, cost, and volume of pumped storage, as well as plant costs. With daily and seasonal variations in demand, and coupling domestic with industrial demand, the optimal pumping and storage regime can be determined by energy management systems using multi-site corporate constraints – in addition to traditional single site stability constraints.

A good corporate energy management strategy should therefore take into account, among other factors, the physical water network, actual energy costs, and demand throughout the wider region of use.

Regulatory Compliance & Operations Intelligence Operational decision-making in complex systems is aided by the use of performance or operations dashboards. These dashboards can provide a holistic view of both operations as well as other systems of record, such as regulatory compliance. The use of contextualised performance dashboards is advocated,

Complex multi-plant systems need operational intelligence as well as information aggregation 28 industrial automation asia | August 2010

which enable rapid drilldown from key performance indicators to understand the source data, providing visibility to the underlying capability constraints, overloads, and potential areas of improvement.

Providing a good top-down operational dashboard enables the quick review of targets and position, as well as rapid diagnostic response when targets go beyond limits. This is critical for developing infrastructure in rapid rollout environments, where new operational teams need contextualised operations help and diagnostics to assist them in making the right decision in a short time.

Just as the supply of water is inextricably linked to its environment and the water cycle, so too, are water supply boards now part of a broader integrated user community – who collectively form an ecosystem that acts in concert to create a sustainable water supply environment.

Therefore, the language of quality is ‘sustainability’ (economic, social, and environmental) where knowledge, information, and decision support become part of the culture of the ecosystem. The creation of an operationally intelligent system looks at the following key requirements:

The architecture of a corporate energy management module in operations intelligence

Benefits Of Operations Dashboards

- Display dashboard information so that key people can make informed decisions. By

incorporating key operational context in the dashboard structure, operational intelligence enables fast drilldown to factors directly impacting KPIs as and when they occur, inviting and suggesting a more rapid targeted response to sudden deviations from compliance.

- Optimise in real-time the cost/volume handled curve for energy usage in pumping, filtration, dosing, recycling, and desalination,

1. Correlation of plant Key Performance Indicators (KPIs) in a wider context relevant to the ecosystem 2. Making KPIs available to a wider community

3. Optimise in real-time, the energy cost/water volume treated/delivered curve 4 . P rov i d e co nte x t- s e n sit i v e , mu lt i - site dashboards for performance and regulatory compliance

5. P rov ide a nd sha re more w ide spre ad measurements for real-time analysis

Corporate Energy Management It is necessary to buy energy at spot prices in order to pump, recycle, or create clean water. How can the optimisation of energy use be managed to achieve this objective at minimal cost and minimal environmental degradation or depletion?

An appropriate, optimal set of operating points may be determined by including technology that enables the collection of real-time data for energy metering, the continuous optimisation of an appropriate cost function, and a quantitative measure of run-time and environmental depletion margins. Including an operational intelligence module like corporate energy management will enable decisions for energy consumption optimised against flow, quality, storage, and environment – such as changes to pump scheduling, plant operations, and plant area logic sequences.

The availability of combined KPIs, in-plant sensitivities, and their downstream usage KPIs, provide the overall day-to-day operations management with a better footing for review and discussion with water end users. Given the advances in end-to-end supply chain monitoring, the appropriate reporting technology, and behavioural incentives across the water supply chain enables industrial users to become part of the responsible ecosystem — and assist in the

and balance out the availability and storage of water in the cost equation.

- Measure plant data using analytic instruments.

Capture this data in real-time at the source, and aggregate using Supervisory Control And Data Acquisition (SCADA) and multitier historian technologies. Use aggregated operational data to provide quantitative data to drive the higher level operational intelligence applications.

overall management of a scarce resource within the developing community.

Water is becoming an increasingly scarce resource, and the management of it more complex, being bounded by energy constraints, infrastructure, and population shifts. The UN’s Millennium Goal targets relating to the environment, particularly water, provide impetus to use technology to enhance engineering efficiency, aid the rapid rollout of new plants, and achieve new regulatory requirements — for simple and multi-site water utilities, economic cities, and large-scale industrial users within the wider ecosystem.

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- Understand not only energy data, but more importantly the context of that usage. Rather than just runtime measurements, perform runtime measurements in context. These key time-based periods allow any measurement data to be aggregated and reported in a more meaningful way, so that good quality, shared decision-making can take place.

August 2010 | industrial automation asia 29

control point

Distribution Management Systems:

Smartness

In Control

Integrated SCADA/DMS innovations place analysis and control functions in the hands of grid operators.

By Marina Ohrn and Hormoz Kazemzadeh, ABB Power Systems, Network Management

O

ver the last decade, the electric power industry has experienced unprecedented change. This has been fuelled both by technological breakthroughs and by the restructuring of the industry itself. Restructuring has seen many utilities move from a regulated environment to a more market-oriented paradigm.

At the same time, the Information Technology (IT) systems that supported transmission and distribution operations have become more robust and powerful, and have now reached the point where multiple applications can be presented on a single platform. The future grid will be largely automated, being able to apply intelligence to operate, monitor and even heal itself.

Intelligent Control As distribution systems become ‘smarter’ and more secure, the operations centres that control

30 industrial automation asia | August 2010

them are also changing to take on new roles in managing the evolving grids. The separate IT systems used in control centres are becoming more streamlined and are communicating seamlessly to provide an integrated monitoring and management system.

A n a l y t ic a l s o f t w a re a n d other advanced applications are providing more far-reaching analyses and are permitting automated operations. The control systems of operations centres are not only helping to make the grid smarter, but are also helping to improve support for operations, maintenance and planning. Such integrated operations centres are aiding distribution organisations in meeting their goals despite increasing demands.

Within the last few years, seve ra l i nte rcon ne c te d but external factors have accelerated the development and expansion

of applications for smart grid te c h n o l o g y. T h e s e i n c lu d e s o c i e t y, g o v e r n m e n t , t h e changing business environment and technology.

The growing role of renewable energy and distributed generation and the associated demandresponse issues are calling for fresh approaches in grid management.

Market liberalisation and power trading are furthermore permitting end users to choose the source of their power. Another important contributor is the increasing cost of generation and transmission, both in terms of infrastructure and fuel.

From a business perspective however, distribution organisations are also looking to smart grids.

This is to help them to maintain or improve reliability, increase asset utilisation, deal with ageing infrastructure and to reduce the impact of knowledge loss as employees reach retirement age in many parts of the world.

Another significant enabler of the development of smart grids is technology – many of the required tools and capabilities were simply not available some years ago. One such resource is communication.

Distribution companies can now choose between many different means of communication: they can use a dedicated network that they themselves own (eg: SCADA radio networks), or use third-party infrastructure (eg: cellular communications). Various factors may influence such a decision. One trend, however, is definite: the importance of twoway communication looks set to increase.

The number of distribution equipment items on the feeder featuring sensing, data processing, control, and communications capabilities is increasing. Smart devices and appliances are even entering home networks. The

Systems Integration Benefits Three important areas of systems integration a re Distribution Management Systems ( DMS) integration with Supervisory Control and Data Acquisition (SCADA), Advanced Metering Infrastructure (AMI) integration with DMS, and the integration of data from substation gateways and Intelligent Electronic Devices (IEDs).

Available functionality now includes the transfer of status/analog points from SCADA to the DMS; the sending of supervisory control and manual override commands from the DMS to the SCADA system; and an integrated user interface running on the same PC operator console

with integrated single sign-on for users.

Utility grid operators are seeing tangible benefits from the implementation of integrated S C A DA / D M S s y s te m s . T h i s includes increa sed operator efficiency within one system, thereby eliminating the need to use multiple systems with potentially different data. It also includes integrated security analysis for substation and circuit operations to check for tags in one area affecting operations in the other, and streamlined login and authority management within one system.

Operators have also noted improved, consolidated system suppor t for DMS, Outage Management Systems (OMS) and distribution SCADA. Much of the discussion about

developing the modern-day smart grid has, until now, revolved around the potential of AMI and emerging advanced metering technologies.

A s a re sult, the number of installations of AMI systems is growing. Ways for distribution grid operators to improve the leverage of AMI data are being developed. Interfaces between AMI, Meter Data Management (MDM) and SCADA/DMS have been created and improved for outage notifications, meter status queries and restoration notifications.

Resulting benefits include: reduced customer outage times and a more efficient use of resources in the field. The use of other AMI data in DMS applications, such as voltage indications and intervaldemand data, has also been explored. Benefits of these include better voltage profiles throughout

ENQUIRY NO. 152

deployment of this technology will depend upon the development and unification of interoperability standards.

August 2010 | industrial automation asiaâ&#x20AC;&#x192; 31

control point

The coordination of and communication with field crews is an important aspect of network management

the system and an improved understanding of system loading.

Additionally, many distribution organisations are enhancing substation automation and the number of substation gateways on their systems. This improves access to information in the IEDs that are installed in substations and distribution systems. The advanced communications capabilities that many of these IEDs possess, include more intelligent recloser controls, switch controls, and voltage regulator controls.

Integration of these systems with the DMS allows for decentralised control at the substation/feeder level, while providing system optimisation through the DMS at the system level. Integrating SCADA/DMS with other utility systems provides an integrated operations centre for managing the smart grid.

Centre Of Operations A smart and fully integrated distribution operations centre will include DMS applications for the management of the distribution systems with respect to efficiency, volta ge cont rol, e qu ipment loading, work management, outage management and reliability. These applications utilise a model that is based on the distribution database and electrical network topology.

The network model uses data from a Geographic Information System 32 industrial automation asia | August 2010

(GIS), and is periodically updated to retain accuracy.

A central aspect of a smart and integrated distribution control system is the integration of the various IT systems found within it. Many distribution companies are expanding the reach of SCADA beyond the distribution substations and onto the feeders, allowing for improved situational awareness and control of the distribution system. Interfaces to other systems include AMI and MDM systems, and substation/feeder gateways and data concentrators.

The strateg y for sha ring between the integrated operations centre and field devices will differ from one distribution organisation to another. There might even be

several approaches used within a single utility.

The network manager platform provides applications that use the network model to provide recommendations for optimal network operation. The platform includes built-in advanced DMS applications for power f low a na lysis of the distribution network, optimal operation of capacitors and regulators, and fault and restoration switching analysis for faults and outages.

T h e n e t wo r k m a n a g e r ’s Distribution Power Flow (DPF) application is an integrated application that prov ides unbalanced power-flow solutions for the online analysis of the realtime network, on-demand analysis of ‘what-if’ scenarios in simulation mode, and automatic analysis of service restoration switching plans.

The DPF application is designed to accommodate large scale distribution models extracted from GIS and provide fast solutions in realtime. The application can support distribution networks connected in meshed configuration and includes multiple swing sources, electrical loops and underground phase loops.

The Volt/Var Optimisation ( V VO) application enables a distribution company to minimise

The operation centre system of the future integrates various IT systems as well as field devices and customer information.

peak demand and reduce real power losses. This defers the need for additional generation, transmission, and substation capacity, lowers fuel and power purchase costs, and hence reduces greenhouse emissions.

The VVO application monitors the distribution network and computes the optimal distribution control settings by minimising a weighted function of demand, loss, and voltage/current violations in three-phase, unbalanced and meshed distribution systems. The application computes the optimal control settings for switchable capacitors and tap changers of voltage regulating transformers.

Rectifying Problems The Fault Location (FL) application utilises short-circuit analysis and can help significantly reduce

Customer Average Interruption Duration Index (CAIDI) and System Average Interruption Duration Index (SAIDI) values. This is achieved by reducing the time that is required for troubleshooters or repair crews to locate system faults. The application computes the possible locations of faults on distribution circuits by looking at fault current measurements and realtime network connectivity.

The Restoration Switching Analysis (RSA) application provides the operator with a quick method to identify switching options to isolate a faulted area and to restore power to as many customers as possible without creating new overloads. The application computes and analyses switching plans to isolate a specific fault location and to restore power to customers that are isolated from the fault zone.

These applications provide decision support to operators in manual mode and support fully automated operation without operator intervention in automated mode. As utilities move toward smart grids and utilise better data and more advanced technologies, advanced applications will increasingly be run in automated modes, further improving reliability and efficiency of distribution operations.

Looking Into The Future The integrated operations centre could be a key to the smart distribution grid. The overall operation of distribution systems is likely to become more complex.

Growth of distributed generation and energy storage will affect power flow on the system. Demand response, whether controlled by the electricity provider or the consumer,

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ENQUIRY NO. 143

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August 2010 | industrial automation asia 33

control point

should also impact power flow and voltage profiles.

In addition, there is a growing t re nd to deploy addit iona l intelligence in devices on the distribution system, such as IEDs, substation computers and gateways, sensors, and advanced meters. Some of these will result in additional local control actions, further amplifying the complexity of distribution systems’ operation.

With increasing decentralised intelligence and control, the integrated operations centre will be a centralised way of overseeing and coordinating the entire system.

Investments are being made in the further development of integrated operations centres for smart distribution grids. This includes both the integration of existing systems and the development of new applications.

Smart grid operators will have a comprehensive view of the distribution system, including system status and monitoring, control, outage response, planned work, optimal equipment loading, and improved control over distributed generation, energy storage and demand response resources.

ENQUIRY NO. 5302

Integration Enhancement Advances in computing have allowed major developments in the evolution of distribution networks The 1970s saw the introduction of SCADA and Energy Management Systems (EMS).

This was followed by market management systems in the 1980s, and OMS and DMS in the 1990s. All of these solutions have been developed and enhanced over the years. A more recent direction of system development has been toward a higher degree of integration in the form of a common platform.

Enhancing Efficiency This network manager platform fully integrates the above applications and also includes a DMS – an operations management system that is designed to help utilities to reduce operating and maintenance costs while enhancing customer service. The DMS provides advanced network modelling and management, integrated switching and tagging, trouble call and outage management, crew management, and also handles the recording and presentation of events.

Power control traces its origins to the 1920s when companies supplied their first remote control systems for power plants.

It was not until the 1960s and the advent of computerised process control, that modern power network control systems became possible.

At that time, SCADA systems were usually designed exclusively for a single customer. They were proprietary and were closed off from one another. The resulting difficulties in coordination meant

34 industrial automation asia | August 2010

that networks remained vulnerable. There was therefore a need for strategies that could prevent faults from developing into outages of the scale of the 1977 New York blackout.

The 1980s saw computing technology advance further. Methods were developed to model large-scale distribution networks in a standardised way. Similarly, SCADA and EMS became more sophisticated, providing transmission operators with better tools to control bulk power flows.

In the business world, the 1980s were also an era of deregulation. With airline, telecommunications and natural gas industries all being liberalised, regulators and utilities both began to consider whether the same could be achieved for electric power.

Such a move would have called for entirely new types of IT systems (mostly to serve the wholesale markets), as well as enhancements to existing SCADA/EMS technology. Perhaps not coincidentally, the generation of control systems that emerged by the early 1990s was able to fulfil these demands.

Progress in computing also changed DMS and OMS. DMSs had originally been distribution-level extensions of SCADA/ EMS systems or stand alone systems, but the unique demands of distribution operations made them more distinct.

Classical monitoring and control systems for distribution networks were relatively low-tech. Typically, such a system was based on a wall board displaying the

system’s status. Such a board would often be covered with sticky notes and pushpins concerning ad hoc changes.

Monitoring Improvement This made the overall system difficult to monitor and inflexible and also presented security challenges. The distribution circuit maps used for maintenance work were paper based. They were often annotated manually and risked being out of date.

The orders used to plan, execute and track scheduled switching on the system were also paper based. Outage calls from customers were received by operators who did not always have direct access to all the necessary information.

These outages were also tracked with paper-based tickets. Communication with crews in the field was radio based. Crews had to inform the operating centres of their location, and the communication of switching, the placement of tags and other operations were coordinated verbally.

As technology and business needs changed, so too did many distribution operations centres. Many SCADA systems were extended from the transmission system to cover the monitoring and control of distribution-side Medium-Voltage (MV) feeder breakers. In some cases, the reach of SCADA was even extended out beyond the MV feeder circuit breaker to equipment such as reclosers, switches and capacitor switches.

ENQUIRY NO. 5303

ENQUIRY NO. 150

control point

SCADA:

Easy

Field Access

C

The World Wide Web opens windows for technologies that allow operators to remotely monitor equipment and facilities. By Alex Hsiao, director, Advantech Green Energy Product Division 36â&#x20AC;&#x192; industrial automation asia | August 2010

ompanies are considering u s i n g t h e I n te r n e t f o r Super visor y Control and Data Acquisition (SCA DA) to provide access to real-time data display, a la r ming, t rending, a nd rep or t i n g f rom re mote equipment. The Internet makes it simple to use standard Web browsers for data presentation, thereby eliminating the need for proprietary host software.

It also negates the cost a nd complex ity of long dista nce communications.

Supervisory Role WebAccess, for example, consists of three parts: Project Node, SCADA Node and Client Node.

Project Node is the development platform. SCADA Node is the data acquisition and supervisory control node, which is connected with field hardware. Users in Client Node can remotely view data and live pictures on the site. Engineers can create, configure and manage projects with the ability to view and control real-time data through ethernet or Internet. The

technology also supports Thin Client, allowing the use of mobile devices to access system data.

T he te ch nolog y a llows operators and users to monitor equipment and facilities directly using web-enabled full-motion video cameras, audio and web cams. It supports the use of live video cameras that are Internet Protocol ( IP) - enabled via an ActiveX control, Windows Media Player, JPEG and other formats supported by Internet Explorer 6.0 (or later).

The video images appear in the same display area as graphic displays, alarms and trends. Optionally, videos can be launched in a ‘pop-up’ window.

Also supported are pushbutton key macros to call up v ideo cameras. Scripts can be used to automatically rotate between

Building automation and facility management

multiple cameras and send PointTilt-Zoom (PTZ) commands.

The browser-based software package can be used in industrial applications and vertical industries including environmental control and monitoring systems, facility control and monitoring system, intelligent building automation, factory process

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August 2010 | industrial automation asia 37

control point

telecommunications, control and architecture technologies. Not only do they represent the cumulative technological capabilities of a city, but they also symbolise the power of the companies and corporations located within.

A multinational entrepreneur group was developing an office centre in China with the goal of establishing a modern intelligent building. They were looking for a control system with integrated automation software to link the building monitoring system, guard monitoring system, access control, and parking management system.

The monitoring software needed to support the LonWorks Modbus bus standards, including Modbus, SOAP, XML, HTTP and other communication protocols. It also needed to support plug-and-play protocol intercommunication, and DDE, OPC, ODBC, SQL, API and other data access methods with open and intercommunication capabilities.

The system has to provide a n application development env ironment that facilitates planning, designing, constructing, maintenance and management.

The system servers’ operating platform need to support Microsoft Windows NT 4.0, with an upper bus speed of 100 Mbps ethernet to ensure high-speed operation.

The system is also required to suppor t a multi - protocol intercommunication control system that can leverage on the Internet and ensure decisiveness and integrity of real-time control, allowing access from a range of remote locations.

The system uses a distributed control system, divided into two levels of network construction.

The first level is ethernet, the second level is the bus, that is, the data transmission network between internal control host and controllers inside all sub systems.

These two levels of network share data within all sub systems through 38 industrial automation asia | August 2010

Some of the industries where SCADA is used are electric power monitoring, wind farm management and process management

standard data interfaces, including ODBC, DDE, OPC as well as Modbus and Lonworks bus protocols.

Command & Control The IBMS system includes building automotive control system, guard monitoring system, and access control and parking management system. The building automation control system includes cold and hot source systems, air-conditioning and airing systems, lighting control systems, transformer and distribution electric systems, water supply and drainage systems, lift systems, and intercommunication information with other sub systems.

It monitors water supply and drainage, electricity transformation and distribution, lighting, lift and other equipments’ operating co nd it io n a nd m a l f u nc t io n alarming, along with operation and detection in parameter changes (temperature, humidity, flow,

pressure, current, voltage, etc).

The guard monitoring system includes a closed circuit television monitoring system, theft alarms, channel management control and watchman system’s data capture and state control. The parking management system’s equipment r u n n i n g s t ate , m a l f u nc t io n alarms, vehicle flow statistics and charging statistics are displayed through standard data interfaces prov ided by ma nagement system software.

SCADA is a term that is used broadly to portray control and ma na gement solutions in a wide range of industries. Some of the industries where SCADA is used are water management systems, electric power, traffic signals, mass transit systems, environmental control systems, and manufacturing systems.

ENQUIRY NO. 5304

Warehouse Security:

Eyes, Ears& Minds

Security cameras are evolving from simple surveillance to gathering vital business intelligence. By Oh Tee Lee, regional director, South Asia Pacific Region, Axis Communications

C

oncerns in wa rehouse management typically focus on the perennial need for better surveillance and security, a task that has been enhanced

by Closed Circuit Telev ision (CCTV) cameras. However, with the growing rate of Internet adoption and broadba nd penetration in Asia, companies are now paying greater attention to t he potent ia l of I nter net Protocol (IP)-based solutions that offer a higher return on investment in infrastructure, improved efficiency and conve n ie nce for e mploye e s – a n d m o r e s i g n i f i c a n t l y, a previously untapped opportunity to gain research

data that can enhance the entire business process.

With the se tools a nd developments, network video surveillance has improved upon analogue surveillance systems.

Its applications in warehouse management increase safety, security and results, and can give businesses an edge over their competition.

Where Tradition Falls Short Vide o su r veilla nce is of ten a cr ucia l element to a loss prevent ion prog ra m, act ing b ot h a s a de te r re nt a nd a source of evidence. However, much of today’s analogue video equipment is unable to adequately

detect criminal behaviour and alert personnel due to poor video quality – as analogue surveillance cameras are only capable of video resolutions equivalent to 0.4 megapixels.

B l u r r y, l o w r e s o l u t i o n analogue images often fail to provide conclusive evidence in theft prosecutions or insurance fraud cases, such as bogus injury or property damage claims.

On the other hand, digital video surveillance cameras provide significantly higher resolution and superior zooming capabilities.

Sufficiently good-quality recorded images are invaluable in resolving any disputes with customers, transporters and other stakeholders, as well as to serve as job safety training materials meant to educate employees on how they can prevent repeat mistakes or accidents.

Digital surveillance systems are also more efficient as they do not re qu ire some one to be constantly monitoring the monitors. Their concentration never wanes, unlike the average p e r s o n ’s r e l a t i v e l y s h o r t attention span of approximately 2 0 m i nu te s . M a n a g e r s c a n specify the built-in intelligence to ‘watch’ for certain behaviours, events and actions with the pan/ tilt/zoom (PTZ) functions. The motion detection feature then sends email alerts and captured images of suspicious activities to office headquarters or even personal handheld devices.

Unlike CCTV systems which only allow viewing from a main control room, systems can be programmed to activate the Camera Explorer remote viewing function when an alarm is triggered, so that personnel from any location can evaluate the situation and determine if it is necessary for a person to conduct a physical check of the site. This improves monitoring capabilities, particularly after regular business hours and on weekends.

August 2010 | industrial automation asia 39

software & Networks

Creating A Network Another advantage of having cameras connected to a network is that surveillance can be carried out live by multiple parties from any location through any device that has either a wired or wireless Internet connection. This results in a greater degree of coordination both within the company through a Local Area Network (LAN) and with external partners.

This is a technological leap from the analogue system in which each camera has to be linked to a network video recorder in order for the recording to be shared. If staff from another warehouse or at headquarters want to monitor the contents or activities of a particular site, the video then has to be duplicated and mailed.

The reduction in time and hassle increases the company personnel’s ability to respond more quickly in any scenario; be it in reaction to a dangerous situation such as a fire hazard, or to a routine re-stocking of inventory.

Compared to the non-scalable time-lapse recordings of CCTV systems, digitised archives can be easily reviewed without the need to search through hours of video for a particular incident.

Time, money, space and storage are saved as tapes are made obsolete. Digital surveillance system s ca n cent ra lise t he management of video feeds and store all recordings on a hard disk drive or server, just like any other data.

The use of IP infrastructure provides managers the option of implementing archiving and recording at two separate locations – recordings for one month can be stored on a local hard disk drive while a separate Network Attached Storage (NAS) product holds a second month’s data. Backup copies of images and recordings can also be programmed to be sent out and stored off-site for greater security.

40 industrial automation asia | August 2010

Sufficiently good-quality recorded images are invaluable in resolving any disputes with customers, transporters and other stakeholders.

Maximising Coverage Digital sur veillance systems save cost s incur red in t he separate installation, support and maintenance contracts of proprietary CCTV systems as they integrate into and leverage upon companies’ existing IT infrastructure, expertise and policies such as authentication, data security and more.

This streamlines the system implementation process and provides a greater return on investment in infrastructure.

Unlike analogue surveillance systems which require special cabling, IP-surveillance systems run on ordina r y ethernet networking. It uses Power over Ethernet (PoE) technology that allows a single network cable to both supply power to the camera and transmit data, effectively eliminating the need for dedicated wiring. By negating the need for cabling, the system extends the area that can be monitored – it gives managers the flexibility to expand the surveillance system and to install cameras in areas where there is limited room for human access.

Cameras can also be mounted directly onto equipment such as stacker-loaders to enable them to

be remotely operated. Infra-red sensors can then be installed to send out alarm signals whenever a ny problem s, such a s t he improper storage of goods, are detected. When alerted, operators can use the network cameras to remotely inve stigate a nd execute the appropriate countermeasures to prevent damages or even the suspension of the entire operation. This automation improves work efficiency in the wa rehouse a nd reduce s the possibility of operation accidents.

One of the most impressive aspects of digital surveillance systems is its combination of high quality image recording and easily searchable archives with software management tools. Every aspect of the warehouse and its processes can be tracked, from the movement of employees and visitors, the condition of inventory to the exact percentage of stock in the warehouse at any given moment.

Video ev idence ca n be combined with time-lined records for cross-referencing or to be analysed for areas of improvement.

Certain patterns of behaviour or trends may be more easily gleaned from visual data, and these findings can be shared within the company and with partners, such as retailers

and transporters, to foster greater efficiency and coordination.

This coordination is likely to become an increasingly vital and sophisticated process as businesses embrace the concept of real-time retailing. Instead of viewing sales as a product of days, months or seasons, retailers now have to adapt to a faster pace of responsiveness to consumer demand.

networks to communicate and t ra n sfer in for mat ion w it hin or between locations. Remote monitoring reduces unnecessary labour and worry by allowing managers to make preliminary a s s e s sm e n t s b e fo r e t a k i n g action and freeing them from the limitations of being physically bound to a single place.

Network video surveillance is now emerging as a tool for gathering business intelligence and applications beyond mere security. With its pairing of quality images and powerful intelligent software such as video analytics, today’s surveillance systems can be the eyes and ears, and also the brains that help a company to improve its operations and get a leg up on the competition.

ENQUIRY NO. 5401

ENQUIRY NO. 148

Inventory Control This affects their operational processes a nd how they manage their inventory – the ideal scenario being stocking a m i n i ma l a mou nt of p a id for inventor y while lowering the occurrence of out- ofstock situations on the selling floor. Therefore, warehouses, transporters and retailers have to constantly exchange real-time

or near real-time information to facilitate a hig h level of synchronisation to efficiently meet the needs of consumers.

Good warehouse management r e qu i r e s co o r d i n a t i o n a n d security to be carried out by a cost- effective a nd flex ible method, customisable to different types of inventory and activities.

Analogue surveillance systems may not be able to provide the quality and scope that is needed in the thorough monitoring, efficient storage of recordings and the remote viewing function that digital surveillance systems can.

Digital surveillance systems are also more cost efficient – such systems are usually easier a nd c he ap e r to i n sta l l a nd operate. They can be integrated into existing IT infrastructure and can leverage on established

Autotek for Industrial Automation - edisi2.indd 1

7/6/10 11:58:15 AM

August 2010 | industrial automation asia 41

instrumentation & Measurement

Ultrasonic sensors provide a means to accurately perform measuring and quality checks â&#x20AC;&#x201C; even in confined spaces. By Daniel Dossenbach, product manager Sensor Solutions; Sarah Jess, Baumer

Precise Detection

Sensors With

T

he development of the personal computer and the cell phone has demonstrated the trend towards miniaturisation. Typically smaller components have to be manufactured for such products. The Printed Circuit Boards (PCB) that are employed have to be assembled with increasing precision in order to comply with the required performance and size.

Process Examination The small Surface Mount Device (SMD) components

42â&#x20AC;&#x192; industrial automation asia | August 2010

that are used for PCB equipping are mostly packaged in blister belts that are inserted into the feeder of a pick-and-place machine. During the packaging process of these components in the manufacturing plant, their presence in the blister belts has to be checked.

Only after this is ensured can the belts be welded up and delivered to the customers. Precisely working sensors are needed for this task. They ensure that the pick-and-place machine can work properly without grasping at nothing.

Light Comparison In contrast to photoelectric sensors it does not work with light but with acoustic waves. It can therefore detect a variety of different media reliably â&#x20AC;&#x201C; independent of their transparency and colour. Neither high-gloss surfaces, highly transparent objects nor the texture of the medium influence the measurement.

Conventionally operating ultrasonic sensors send out conical acoustic waves. As a result, their spot size is too big for measuring into openings of less than 10 mm in diameter. To avoid these limitations, ultrasonic sensors are equipped with a special beam columnator that concentrates the acoustic waves, which allow for the sensor to measure into small openings.

Apart from the described filling of blister packages with electronic components or pharmaceutical products, this feature is advantageous for the detection of wafers of photovoltaic cells through small openings. Depending on the preferred installation, the sensors are available with the columnator on the short or long side.

The nozzle is removable and exchangeable, which facilitates the cleaning and maintenance of the sensor.

The sensor family can be used in a range of applications to detect objects and liquids in containers of any size.

Fast and Flexible The minimum response time of the Series 09 ultrasonic sensors amounts to only 7 ms. With a housing width of only 9 mm, the sensors can be cascaded in a confined space. By this means, sensors that are arranged in-line can scan a large surface or several openings in one single cycle. This reduces the scanning time considerably and

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ENQUIRY NO. 147

Some of the most important sensor features demanded by manufacturers and users are a high measuring speed as well as independence of transparency, colour, and reflection. There is also little space to check the tiny components.

The cavities of the blister belts are sometimes narrow, but the sensor nonetheless has to detect any discrepancy as quickly as possible. Additionally, it must be able to identify any components, regardless of their texture and appearance.

Ultrasonic sensors are based on the principle of measuring soundâ&#x20AC;&#x2122;s time of flight through the air.

Ultrasonic waves that are not audible to the human ear are emitted by the sensor, reflected by an object and again received by the sensor. As a result, the sensors operate completely contact-free.

Especially in the lab, several advantages result from this operating mode, as neither the medium to be analysed nor the sensor are contaminated during the measurement. Additionally, an ultrasonic sensor is particularly resistant to humidity and dust, which makes it consistently reliable.

August 2010 | industrial automation asiaâ&#x20AC;&#x192; 43 JEC Asia 2010_80x241_IAA_GB.indd 1

08/07/2010 16:32:20

instrumentation & Measurement

Detection of small pipette tips in the laboratory with ultrasonic sensors

Ultrasonic sensors with beam columnator on the short and long side as well as cable or flylead connectors

is, for example, useful for the presence check of tablets.

At the same time the sensors achieve a high resolution and repeat accuracy of up to 0.1 mm.

Various possibilities for installation provide flexibility for the sensors’ insertion into automation systems. Depending on the requirements, the sensors are installed vertically or horizontally and can be fixed from above, the side or from below with a single screw – making the installation simple and efficient.

The sensors are available with RS232, analogue, or digital interface, the communications standard IO-Link and cable as well as flylead connectors. Therefore, an easy connection to a number of controls is enabled and the exchange of data, condition information, and configuration parameters are possible. These features ensure control over the process.

ENQUIRY NO. 5501

Other Applications Sensors can perform other tasks besides the detection of small objects – they inspect levels of mascara, creams or the like during the packaging process. Additionally, the sensors ensure that contact lenses are packaged according to hygiene standards by reliably detecting the level of saline solution in the blister package. When capsules are to

44 industrial automation asia | August 2010

be filled and packaged, the ultrasonic sensors can check the presence of the capsule halves as well as detect the fill level within.

The sensors are also employed in laboratory automation. They detect the fill levels in the cavities of micro containers.

Due to the special concentration of the beam waves, they are able to measure

into the openings, which are sometimes only 3 mm in diameter.

The sensors check whether the quantities are sufficient for the analysis and if too much liquid has been filled into the wells. This helps to minimise waste and avoid incorrect analytical results.

ENQUIRY NO. 5502

T

he detection of any objects or persons – the job of a photoelectric sensor. A s simple as this may seem, the challenge is to produce a sensor that ca n work effectively in ambient conditions, while being affordable at the same time.

Ensuring Accuracy Precise and reliable detection are needed for presence checking, positioning a nd counting in automated processes, which are the core functions for a photoelectric sensor. In today’s marketplace, there are a number of sensor types, housing different technologies.

Certain de facto standards have been established for miniature photoelectric sensors. One pertains to the placement of mounting holes in the device. Mounting is achieved via two holes that are placed an inch apart, at the front of the sensors.

Examples of standards that are used in other aspects of the sensor are DeviceNet, M8/M12 Plug and USB. What many of these standards have in common, are that they have been generated out of open technologies developed by private companies.

Stable metal threaded inserts allow simple and robust mounting without lock nuts. Even tightly fastened screws do not present a problem. The sensor comes with a visible light spot produced by PinPoint LED, which aids in fast and accurate alignment. The light spot technology is unaffected by peripheral lights.

It is designed with a rotary potentiometer for easy adjustment with the use of a crosshead screwdriver. Two Light Emitting Diodes (LEDs) behind the semitransparent back of the sensor, display the status of the sensor – which is visible from any direction.

Reliability of the sensor is mainly driven by the optics and electronics.

The Application Specific Integrated Circuits (ASIC) chip’s programmed

Photoelectric Sensors:

Working

Reliability

Sensors need to be easy to set up, adjust and perform effectively in a variety of environments.

By Adrian Schwarz, product unit manager, Business Unit Photoelectric Sensors & Fibres, Sick intelligence suppresses the influence of ambient light such as sun beams, flashing lights and room lighting.

Using light coding, the sensor does not react to other sensors, resulting in no cross talk.

Interference from surrounding electromagnetic fields also does not impair the performance of the sensor.

ENQUIRY NO. 5503 August 2010 | industrial automation asia 45

sector spotlight

Logistics:

Fast Forward With

Storage W As businesses in Asia progess in the seafood industry, the advancing technology provides better solutions for storage when dealing with rising demands. By Brian Miles, MD, SSI Schaefer, Asia Pacific & Middle East 46â&#x20AC;&#x192; industrial automation asia | August 2010

hen it comes to seafood storage, Asia is still lagging behind the US and European markets in terms of the technologies invested. This is mainly because of the lower cost business models employed in the region where justification on a good Return On Investment (ROI) is difficult.

However, as Asia emerges to become the worldâ&#x20AC;&#x2122;s fastest growing region, steeper demands for more technologyâ&#x20AC;&#x201C;based systems and solutions in the supply chain industry for this sector increases.

Mobile Racking System Traditionally, while selective racks are a low cost option with full pallet access, it generally trades off with low storage density as it utilises only around 32 percent of the actual storage area in the warehouse.

For double-deep racks and drive-in racks, the storage density is about 43 percent and up to 50 – 60 percent respectively. However, pallet storage flexibility and case picking opportunities are reduced in these cases.

Therefore, instead of the conventional storage systems, an electrical mobile racking system that provides operatives with up to 75 – 80 percent storage capacity, alongside with 100 percent selectivity, while allowing any pallet to be removed or cartons to be case picked on demand, would be the wiser choice.

Previously believed to be too expensive by the trade, mobile bases can double the storage capacity of the cold store, yet still provide all the facilities of selective racking.

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ENQUIRY NO. 079

Cold Store Supply Chain With the multi-billion dollar business in seafood production in Asia, food safety is a concern.

Traditionally in the rising markets here, there has been a high spoilage rate from harvested seafood to tabletop. Having a cold store storage facility is the solution to raise the standard for domestic distribution of food to protect people’s heath.

However, for a start, the investment cost to build and run a cold store can be up to 10 times higher than the cost of running an ambient temperature warehouse. This is because it inherently requires more sophisticated technologies for handling goods.

The common approach is to try and reduce the initial set-up outlay since variables such as higher operating cost are inevitable. This, of course, is not the smartest thing to do. This is especially so, in the long run, as space optimisation and higher productivity achievable by using a modern storage system, will pay for itself, with lower running costs and eventually increase profit margins.

Stock rotation is a fundamental requirement in this case, as the shelf life of seafood is limited. With the high cost of building and running a cold store, it is essential that storage solutions offer maximum volumetric utilisation.

August 2010| industrial automation asia 47

sector spotlight

Storage & Retrieval Judging from the increase in the number of warehouses built on the narrow aisle automated storage and retrieval system (AS/RS) recently; it signifies that the usage of more sophisticated systems in the region are on the rise.

This is because many companies have recognised that cold stores are far more difficult to operate manually. This is especially when the temperature generally hovers around -25Ë&#x161;C for frozen food, and therefore justification on the ROI for the usage of automated systems is easier.

AS/RS is a high-density storage facility that is fully automated and transfers pallets via automated in-feed conveyor systems and transfer carriages to pallet racking serviced by storage and retrieval machines.

It therefore reduces the need for labour and energy, while providing a high level of accuracy. A lower cost alternative is to use aisle changing AS/RS system with picking tunnels, and at present, there are two such systems operating in South East Asia.

The radio frequency controlled satellite is suitable for usage in a deep freeze area.

For a Third Party Logistics (3PL) provider in the seafood industry, that translates directly to more revenue, since more customer goods can be stored in the same facility. And for a manufacturer of seafood products, it means being able to store the same amount of pallets in a much smaller facility, something especially significant for expensive build-and-run cold storage warehouses.

48â&#x20AC;&#x192; industrial automation asia | August 2010

Control With Radio Frequency In the current ma rket, where fa st a nd accurate stock replenishment using stora ge solut ions a re in dema nd, a not her high-density storage system that is generating interest in the region is the radio frequencycontrolled satellite system.

Unlike the conventional way of storage using drive in racking, where goods are moved manually into the storage lanes, the radio frequencycontrolled satellite that is suitable for usage in a deep freeze area travels down the lane automatically â&#x20AC;&#x201D; to load and retrieve goods pallet, when placed into the racking systems.

With this system, goods pallets can be placed concurrently into two or more storage lanes. This translates to a more efficient system for the collection and retrieval of goods, which is especially crucial for the time sensitive seafood industry as it operates continuously in a loop cycle.

The cost of the racking for a radio frequencycontrolled satellite system is similar to a traditional drive-in system. Compatible for usage with all conventional forklift trucks, there is no additional cost to replace the existing equipment.

The cost of the satellite is also covered by the increase in efficiency of the forklift truck, as it can now handle a far higher number of pallet cycles per hour. As such, using the system is a faster and more cost effective alternative over conventional storage systems.

ENQUIRY NO. 5601

Pavel MatouĹĄek, Czech Republic

Hazard Control

Law makers are in the process of formulating legislation to manage the use of toxic substances in electronics manufacturing.

By Gary Nevison, head of Legislation, Premier Farnell

T

he European Parliamentâ&#x20AC;&#x2122;s environment committee met in Brussels on June 2. It has agreed to put three substances that were facing an immediate Restriction of Hazardous Substances (RoHS) directive restriction on a list of priority chemicals that will be reviewed later, with a ban being a possibility.

Brominated and chlorinated flame retardants and Polyvinyl Chloride (PVC) will be looked at later along with arsenic compounds and all chemicals, currently 38 of them, featuring on the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) Candidate List of Substances of Very High Concern for authorisation.

Additional Support Green g roups have been lobbying for the three substances

to be banned with support from some consumer electronics manufacturers, whereas most manufacturers are opposed to any such restrictions.

Members of the European Parliament (MEPs) have called for a ban on nanosilver and carbon nanotubes. They have suggested that other electrical and electronic material containing nanomaterials should be labelled, and that manufacturers should be obliged to provide appropriate safety data.

Nanomaterials are materials with small particles and are widely used in many products including sunscreen, cosmetics and paint.

Nanosilver is a biocide that has been used in washing machines, air con and vacuum cleaners.

C a rb o n n a n o t ub e s h av e potential for novel technologies but

there have been few applications by far. Super capacitors and some types of electric motors seem to be the only uses.

At the same meeting, the environment committee agreed that RoHS should become open scope to cover all electrical and electronic equipment, with some exemptions such as renewable energy generation, certain largescale installations, industrial tools, material for military purposes and vehicles. Exclusions would be subject to review in 2014 and the committee suggested that the European Commission propose further exclusions within 18 months of the directive going into effect.

Additional substance restrictions would be introduced by the European Commission. This will use a procedure based on the one used for REACH substance restrictions but ta k ing into account waste disposal issues, especially in developing countries.

The exact procedure has not yet been decided but will be based on proven risk, not only hazards, and on impact assessments that consider all potential alternatives.

Category 11 will be introduced and will capture all electrical and electronic equipment not covered by categories 1 to 10 unless specifically excluded. While not included in the June 2 vote, it is now almost certain that RoHS will become a CE mark directive.

This could create a resource sapping burden for manufacturers, importers and distributors and will establish the need for even more data, information and record keeping throughout the supply chain.

The full European Parliament will vote on the amended RoHS directive in the near future and it could well be adopted by the end of the year. The crystal ball suggests that implementation will be late 2013 or 2014.

ENQUIRY NO. 5602 August 2010 | industrial automation asiaâ&#x20AC;&#x192; 49

energy

Case Study:

ControllingThe Field

Field device management technology is being implemented at Nestle’s renewable diesel plant in Singapore. By Laura Virta, lead engineer, Metso

C

onstruction of Neste Oil’s NExBTL renewable diesel plant in Tuas, Singapore is at its final stage and the plant will be ready for operation by the end of the year. The production capacity of the plant will be 800,000 t/a of NExTBL renewable diesel.

Data Management Field devices that are installed at plant are Highway Addressable Remote Transducer (HART)enabled. The HART protocol is a bidirectional communication protocol that provides data access between intelligent field instruments and the automation system.

At the NExBTL plant, each a v a i l a b l e a d d i t i o n a l H A RT measurement is made accessible to the operators, who use them especially in start-up and shutdown situations. These digital measurements can still be used when the process variables are beyond their normal analogue 50 industrial automation asia | August 2010

measurement ranges, and therefore provide information about the process in exceptional conditions.

In addition, the protocol enables device configuration, device diagnostics and troubleshooting.

As for user interfaces and reporting tools, much emphasis has been based on their design and usability. Each process display has been designed in cooperation with the end users and while they present the process in detail, they also provide vital process information.

The user interface also seamlessly combines the tools needed for operations, reporting and analysis.

The long-term history collection tools can be used by operators for simple trending, or for following process operations. Together with the information management tools, the history collection tools also provide the plant’s operation and maintenance personnel with more detailed monitoring and analysing capabilities.

These information management tools can be accessed remotely.

This makes it possible for example, for production efficiency and performance reports to be viewed at Neste Oil headquarters in Espoo, Finland, or for operations optimisation to be developed further, together with the identical NExBTL plant in Rotterdam, The Netherlands.

Keeping Track Another technology that is used at the site is the DNAfieldAssessor, which makes field device management easier and more efficient by providing easy remote device configuration, calibration and tuning. Online device condition monitoring ensures continuous information on device diagnostics and supports proactive field asset management.

It also helps to control device performance monitoring and the planning and optimisation of maintenance work. Device performance monitoring takes the monitoring of the selected devices to a higher level. Open FDT/DTM technology allows access to third party field devices.

The project implementation took over two years. After the basic engineering, definition and configuration stages, the implementation of all software application and hardware designs were tested. As the commissioning and start-up phases are critical, much emphasis was placed on the factory acceptance test to iron out any complications beforehand and to minimise the time needed for testing onsite. The factory acceptance test period took six months and the testing was performed jointly by Neste Oil, Technip and Metso personnel.

I n S i n g a p o re , t h e l o c a l government has ratified the Kyoto Protocol and has committed itself to reducing greenhouse gas emissions from 2012 onwards.

Singapore, being the world’s third-largest centre of oil refining, occupies a central location in terms of production and raw material flows. The country is ideally placed to become Asia’s hub for biofuels.

NExBTL is a renewable diesel based on technology developed

by Neste Oil. It brings a cost efficient solution to reducing CO2

and local emissions as it can be produced from a flexible mix of both vegetable oils and waste fat from the food industry.

When compared with conventional fossil diesel, NExBTL has a 40-60 percent lower level of greenhouse gas emissions over its entire lifecycle and it also reduces tailpipe emissions, therefore

contributing to better air quality.

Unlike conventional biodiesel, it can be used at up to 100 percent content in any diesel engine.

Existing distribution systems are fully compatible with the renewable diesel and require no additional investments in this area.

ENQUIRY NO. 5701

Demand For Cleaner Alternatives New alternatives are needed to replace poor-quality fuels, as traffic emissions are becoming a major problem in Asia’s growing cities. Nine of the world’s 10 most polluted cities are in Asia. The urban population in the region has increased significantly, due to the rapid economic growth over the last 20 years. Several million people have moved from the countryside to the cities in search of work.

With growth in the use of fuels and vehicles, tailpipe emissions are on the rise and are calculated to be responsible for up to 90 percent of airborne emissions in Asia’s cities and towns today. According to studies, traffic emissions are responsible for tens of thousands of premature deaths every year in the worst polluted cities.

Governments in a number of Asian countries have tried to combat the problem by imposing limits on emissions and improving public transport. In their efforts to clean up urban traffic, many Asian countries have adopted the Euro emissions reduction system. For many years, fuel specifications have been progressively tightened in Europe and this approach is being adopted also in Asia.

However, according to “The Road Map for Cleaner Fuels and Vehicles in Asia” by the Asian Development Bank (ADB), the pace at which emissions are being cut needs to be accelerated and vehicle emissions must be reduced to the lowest possible level as soon as possible. The demand for cleaner alternative fuels produced from renewable raw materials is expected to grow in the region.

August 2010 | industrial automation asia 51

features

Case Study:

Automation For Packaging

Pies & Cakes

A range of automation equipment has made a major contribution to a packaging line in a bakery in the UK.

By Annalisa Belante, Cama

N

owadays, food packaging is more than just putting a product in a box; it is a complex matter of addressing shap e , si ze , mate r ia l s a nd marketing requirements, quicker and with improved safety.

The Italian manufacturer of packaging systems and machinery was faced with a challenge to increase its customer’s productivity.

T h e m a c h i n e b u i l d e r ’s customer is a major player in the packaged cake market that accounts for more than £900 million (US$1,333 million) of its parent company’s annual sales.

The company operates out of a number of locations around the UK , and produces a number of different brands.

The Challenge There are five new packaging lines at this site and one at another UK site, as the end user seeks to increase its productivity. This line is for packing pies at high speeds (typically 25 to 26 cases per minute), while the other lines are more flexible and can be used for packaging cakes as well as pies, either into cartons or flowwrapped. Products of numerous 52 industrial automation asia | August 2010

varieties are received onto the line at a rate of about 200 per minute.

Designed to increase output a nd improve f lex ibilit y, the packing machines replace manual hand-packing systems and allow the use of wrap-around cases. The result is a more flexible system, allowing a changeover of product size and variety in less than 10 minutes, by using a system of moving guides and a series of Programmable Logic Controller (PLC) sequencing programs.

Intelligent merging from two flow-wrapping lines is also possible.

An additional benefit is that the machines have a smaller footprint, replacing top-loading machines that require more floor space.

The final stage of each complete packing line consists of a wraparound case packer and ancillary equipment.

These systems are capable of packing different product types in various configurations. The wraparound case packer for sponge cakes reaches a maximum speed of 25 cases per minute, while the system loads sponge cake trays at about 200 trays per minute, in a wrap-around case.

Another significant change involves the replacement of preprinted labels by case coding. This not only saves on label stocks, but also allows the cartons to be printed on both ends, making identification easier when the cartons are stacked on a trolley or pallet.

Initially, according to the enduser’s engineering program manager, the job was put out to tender with five suppliers and an assessment made based on technical knowledge and sales support.

configuration, process control sequence examples, and safety/ process interlock structures.

Results Due to the integration between the axis control and the PLC, there are no networks to manage, no languages to resolve, no duplication of variables or problems with compatibility or timing and no data to exchange. In addition, the individual components have all been specifically engineered to work together, and each can operate at its maximum potential at all times.

While the individual machine components can communicate via Sercos, the Ethernet protocol is used to manage the settings and to communicate with the corporate supervision system. This way, the parameters can be recalled directly

PCA2010 MagAd(IndAuto)rev(p) 4/16/10 4:51 PM Page 1

from a special menu via the operator panel, and so simplifying work for operators.

Depending on this setting, all other operating parameters are automatically updated. This means that a single person can control the entire packing line, eliminating the time normally needed for specialist personnel to set all the parameters.

“In operation, the single line was our biggest learning curve,” says the engineering program manager. “We moved to this site when we were happy with our other operations. Although a manual changeover could also be achieved in about the same time as is possible with the new systems, much more pre-planning would have been required and hence more down-time.”

ENQUIRY NO. 5801

ENQUIRY NO. 129

Solution For automation control on its systems, the machine builder uses the Rockwell Automation AllenBradley controller and operator interface. The controller controls the machine cycle and its functions, utilising the basic functionalities of the Allen-Bradley software, while the dedicated application software is developed in-house.

Other equipment used include the company’s Human Machine Interface (HMI), motor control, inverters, servomotors and drives, and CPU access control.

The controller’s softwa re include s sta nda rd prog ra m modules for motors, valves, alarms and analogue I/O scaling, standard program modules for Programmable Integral Derivative ( PI D) lo op s, prog ra m s a nd tasks structures, I/O mapping

August 2010 | industrial automation asia 53

features

All One Wireless Sensor Networks:

In

WirelessHART represents a standard that supports a plantâ&#x20AC;&#x2122;s wireless devices, eliminating the need for multiple communication protocols and gateways.

By Jonas Berge, director of PlantWeb Consulting, Emerson Process Management

E

ngineers across different industries are adding value to their plants by using instrumentation based on the international IEC-approved WirelessHART standard. This is in applications to lower automation cost, improve plant performance, and lower operation and maintenance costs. This article takes a look at the enablers of the underlying technology and how some of these early practitioners have overcome plant challenges with innovative solutions that are based on the standard.

The standard is designed for process applications, which is different from other wireless protocols for power grid, factory, building, or home automation.

The standard was designed specifically for process industry needs, based on requirements defined by end-users in 2004 and afterwards verified by the

54â&#x20AC;&#x192; industrial automation asia | August 2010

International Standards In Interoperability WirelessHART is an international standard for wireless sensor networking for process applications and is known as IEC 62591. By specifying devices conforming to IEC 62591, plants are assured that these devices will interoperate with each other, forming the selforganising mesh network and providing access to complete device functionality.

A single network infrastructure supports all the plant’s wireless measurement needs, eliminating the need for multiple communication protocols and gateways. Many manufacturers provide a selection of the standard’s transmitters for flow, level, valve position, pH, conductivity, discrete, vibration, temperature, multiple temperature points, and pressure. Level switch and valve position monitoring as well as wireless adapters for hardwired devices are also available.

New applications become possible as more manufacturers release products. These devices can be mixed in the same network to meet different process application needs based on this common standard.

An unmanned offshore platform in India required remote position indication for the Emergency Shut-Down (ESD) blow down valves. Laying new cable and installing additional field junction boxes for hardwired devices on this operating platform would have been costly and risked damaging existing equipment and cabling.

Position transmitters (as well as temperature transmitters for other purposes) were installed sharing the same gateway. As a result, operators receive confirmation of valve action at a fraction of the cost of a wired solution.

In the future, additional devices can share the same network infrastructure.

All of the standard’s devices use the same commands (which are also the same as wired HART); IEC 61784-1 CPF 9 / IEC 61158 Type 20. This means that there is no need to integrate gateways and drivers for multiple protocols. Automation systems with native WirelessHART support eliminate the need for gateway and data mapping altogether. This is a clean and

seamless solution that is easy to deploy and maintain, and provides a base-level of interchangeability in addition to interoperability.

The standard uses the same commands that have been used in wired HART devices. These include commands for access to the Process Variable (PV), identification, commissioning, calibration, setup, and diagnostics with which technicians are already familiar.

There is no need to learn the different ways to integrate the PVs, identify, commission, calibrate, setup, and troubleshoot devices.

An important difference from hardwired HART, is that WirelessHART uses scheduled burst mode to communicate measurements in real-time, not poll-response.

Plants can mix and match the devices from different manufacturers for different functions – and be assured that the devices will mesh network with each other, integrate with the system and software, and be operated and maintained in the same basic way. This provides freedom in choosing from manufacturers and device types, independent of gateway.

With the standard commands, old or new hardwired HART devices can be fitted with a simple wireless adapter to join a WirelessHART network without arduous configuration. The intelligent device

ENQUIRY NO. 156

Standardisation Association For Measurement And Control In Chemical Industries (NAMUR) at a multivendor test at the BASF Ludwigshafen plant in 2009.

This is why instrumentation and control suppliers are rapidly developing products based on the standard, and plants are applying these in their processes.

August 2010 | industrial automation asia 55 CE ad IAA v1path.indd 1

7/15/10 10:39:34 PM

features

WirelessHART devices are automatically detected and integrated

WirelessHART meets the NAMUR NE 124 wireless requirements

management software part of asset management solutions can now access the device for setup, calibration, and diagnostics etc.

Many wired HART instruments have rich diagnostics and process data, yet this valuable information goes unused because older legacy systems are not equipped to receive HART communications. While it is often too expensive and complicated to access this data through traditional wired means, upgrading devices with a wireless adapter is an easy and cost-effective way to ‘see’ the diagnostic and process information.

A tyre factory in India required radar level transmitters in their utilities unit. Signal wires could not be run but local power was available at the measurement point. WirelessHART adapters were fitted on the transmitters instantly giving access to the measurement as well as all internal intelligence enabling remote setup and diagnostics. Running signal wires would have been far more expensive.

solution, resulting in higher quality product and greater productivity.

To commission a WirelessHART device, the network ID and join key (password) are assigned through the wired HART maintenance port available on all devices, not using wireless communication. This ensures that an outsider cannot ‘overhear’ and use the join key (password). This is a secure way of commissioning wireless devices. The technician uses the same handheld field communicator or laptop software to commission all their wireless and wired HART devices.

A company in India performs turbine performance analysis, going from plant to plant on a periodic basis.

In the past, time was lost due to the need to wire the temperature and pressure sensors to the data acquisition system. Using the standard completely eliminated this time consuming and error-prone step, resulting in reduced testing time and improved productivity.

Easy Maintenance All of the standard’s devices have a wired HART port, compatible with wired HART tools. Existing handheld field communicators or common HART interface and laptop software which technicians are already familiar with, can temporarily be connected to the maintenance port for local setup and device management at the time of commissioning or maintenance. Documenting field calibrators are also able to connect through the hardwired port.

A chemical plant in Australia has a rotating reactor.

The earlier solution using hardwired transmitters and slip-ring connections was prone to frequent failure.

The standard’s transmitters provided a more reliable

Self-Organising Deployment In a full mesh network topology, all devices are capable of data packet routing, thereby ensuring multiple redundant data paths from remote sensors all the way to the gateway. A multitude of powered wireless access points need not be installed throughout the plant – a single (or redundant) gateway will do. Since multiple ‘hops’ are possible, data can be relayed long distances.

If one of the paths is obstructed, interfered with, or otherwise fails, data simply follows another path.

WirelessHART network management automatically establishes and maintains the routing path and backup between devices. No manual configuration is required when adding a device. In addition to reliability, this makes

56 industrial automation asia | August 2010

Interoperability: Application Profile Just like hardwired HART devices, all the wireless standard’s devices have common communication settings: always Time Division, Multiple-Access (TDMA), 10 ms time slot, security on, network manager in gateway, and so on. There is no need for plant personnel to make all these advanced settings.

This minimises the possibility of configuring devices incorrectly. It is therefore easy to enable such

devices to work together – just assign network ID and join key (password).

An ore beneficiation plant in India required monitoring of a 1.2 km long conveyor belt to detect pull, sway, and swing. WirelessHART solved the application at half the price, and increased productivity by its ability to pinpoint the exact location causing the problem, thereby shortening the problem resolution process.

Security measures like encryption, key rotation, authentication, access control list, and sequence number, are only effective when turned on within a system. For WirelessHART, all these security features cannot be turned off; they are constantly on for protection. There is no possibility of inadvertently leaving the security off and the system open for intrusion.

Going Beyond The P&IDs WirelessHART lowers project cost, increases quality and throughput, reduces downtime, lowers operations and maintenance costs. It also reduces the cost of Health/Safety/Environmental (HSE) compliance, reduces energy consumption, and cuts down waste and rework. It is another example of a digital plant architecture that uses the power of field intelligence toSI-492-CF improve plant performance.

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ENQUIRY NO. 155

it easy to add new devices ‘at will’ or to replace devices.

A jetty at a bitumen loading terminal in Australia had problems with cold spots along a 900 metre long heated pipeline, which caused the bitumen to solidify and stop flowing. Transmitters were installed along the pier to measure and relay data back to the operators.

This resulted in catching potential problems before blockage occurred. Hardwired devices and cable trays along the jetty would have been more expensive due to the difficulty of laying the cable.

Just like hardwired HART and other fieldbus devices, WirelessHART devices do not have an Internet Protocol (IP) address, making them more secure as well as independent of the IT department. Since the standard uses IEEE 802.15.4 radio, the gateway does not necessarily use Wi-Fi (IEEE 802.11) radio and has no direct IP addressing.

Therefore, the instrumentation and engineering responsibility is clearly segregated from IT responsibility. The Instrumentation and Electrical (I&E) department can deploy new devices and extend the network at will without liaising with the IT department. Conversely, the IT department can independently control the requirements for Wi-Fi and IP equipment according to their standards.

Not having direct IP addressing also has a security benefit since data is not routed between the upper and lower levels in the network hierarchy.

The standard IEEE 802.15.4 radio that is used

by WirelessHART employs Direct Sequence Spread Spectrum (DSSS) technology – which in conjunction with channel hopping and optional channel black listing, makes communication tolerant of interference and does not create interference with other radios.

The radios used have low power consumption which enables batteries to last for several years. Some devices use intrinsically safe ‘power modules’ that can be placed in a hazardous area.

Flow and pressure of production wells in Brunei had to be monitored remotely. A WirelessHART sensor network was deployed with a Wi-Fi long-distance backhaul network. The two networks coexist and complement each other for a lower cost than an allhardwired or partially hardwired solutions.

August 2010 | industrial automation asia 57

Se

features

In most projects, the type and quantity of field devices are still being evaluated when engineers begin the detail automation designs. The standard’s devices and networks add flexibility to projects. It simplifies many design activities by eliminating wires, including While it is often too expensive and complicated to access this data through traditional wired means, upgrading devices with a wireless adapter is an easy and cost-effective way to ‘see’ the valuable diagnostic and process information.

cabinets, wiring, terminations, cable tray design, fusing, and installation drawings.

It also accommodates changes – device additions, or location changes – easier than with wired devices. Modifications to wireless instrumentation can continue until late in a project. Including the standard as an integral part of the automation design can protect projects from delays and their accompanying cost overruns.

For many new projects everything on the Piping and Instrumentation Diagrams (P&IDs) is currently being wired, but plants are now ‘going beyond the P&IDs’ using the standard. For instance, vibration monitoring of small critical assets such as pumps, motor winding temperature, and position monitoring on hand-operated gate valves – which normally are not connected to the distributed control system.

These incremental measurements lend themselves well to wireless monitoring. Most plants are designed with the minimum amount of wired instrumentation required to run. But to operate the plant with increased attention to improved reliability, increased energy efficiency and improved turnaround planning requires additional measurements.

These are not required to go into the DCS since they are not part of the control strategy, but they are needed to automate asset optimisation. For these areas, WirelessHART is ideal. Plants also deploy the infrastructure to get the ‘add at will’ ability for wireless devices for unforeseen future applications.

ENQUIRY NO. 5802

Enzo Forciniti, Germany

WirelessHART mesh topology is self-organising

58 industrial automation asia | August 2010

& Services productsproducts & Services

Beijer Electronics:

Belden:

The iX HMI solution from Beijer Electronics is designed for packaging, printing, food and pharmaceutical processing machines, machinetools, water and irrigation, petrochemicals and marine applications.

The iX software is supported by the next generation of the company’s operator panels and industrial PCs. It fills the gap between proprietary operator panels and cost-intensive SCADA solutions.

It is available in developer and runtime packages in versions for 250, 2000 and 4000 external tags, as well as an upgrade version regardless of tag size.

The iX Panel series offers both keypad and touchscreen models to choose from. The series is designed for industrial applications and complies with global industry standards.

- Touchscreen models: 3.5”, 5.7”, 6.5”, 10.4”, 15.0” - Keypad versions: 5.7”, 6.5”, 10.4”

Belden has extended its range of Hirschmann products to include the WLAN access point BAT54-Rail Single. This device is designed for mounting on a top-hat rail and can be used both as Access Point and Access Client. Unlike the BAT54-Rail, this access point has only one WLAN interface, making it a costeffective alternative for applications that do not require a second interface.

This access point of fers transmission rates of up to 108 Mbit/s in either the 5 GHz or 2.4 GHz waveband.

Fast roaming facilitates uninterrupted connections, even while changing from one radio cell to another. Network management can be carried out using browser-based, Telnet or Windows software that supports rogue AP detection.

HMI Solution

WLAN Access Point

Enquiry no. 5901

Enquiry no. 5902

Cognex:

Dassault Systèmes:

VisionView VGA from Cognex is a low-cost DIN rail-mount adapter that provides direct VGA output for the application software, allowing operators to connect to any size of VGA monitor without the need for a PC. The software release, VisionView 1.3, supports the TrainFont interactive control for run-time font training of OCR/OCV applications and allows the interface to work with DataMan 200 industrial ID readers in addition to In-Sight vision systems.

The adapter supports VGA resolution of 640 x 480, SVGA resolution of 800 x 600, XGA resolution of 1024 x 768, as well as Mitsubishi GT15 and GT16 touch screens. Users can view images from a single or multiple vision systems on the connected VGA monitor.

Dassault Systèmes has announced the availability of Abaqus 6.10, a unified Finite Element A na l y sis ( F E A ) a nd multiphysics product suite for realistic simulation from Simulia.

The product introduces a multiphysics capability for performing Computational Fluid Dynamics (CFD) simulation. This enables users to perform coupled physics simulations such as fluid-structure interaction between human tissue, a medical device, and fluid flow; thermal analysis of electronic systems undergoing convection cooling; or transient thermal analysis of engine exhaust systems.

Abaqus 6.10 features enhancements to its extended finite element method (XFEM) that improves the process for modelling fracture of composite materials. It also provides performance improvements for parallel processing of simulations that use XFEM, or the implicit dynamic procedure, allowing more simulations to be performed in less time.

DIN Rail-Mount Adapter

Enquiry no. 5903

Simulation Solution

Enquiry no. 5904 August 2010 | industrial automation asia 59

products & Services

Festo:

GE:

The integrated controller FED-CEC from Festo is a space optimised front-end display – a controller created by integrating a processor mo dule b a s ed o n t he CoDeSys software platform.

The integrated C A Nopen master interface allows users to connect directly to the valve terminals and electric drives. An option for the FED-UIM I/O module is available, which offers integrated digital and analogue channels that provide Programmable Logic Controller (PLC) functionality integrated in a panel.

The standard programming of this device is in accordance with IEC 61131-3, CoDeSys. The integrated controller communicates with controllers from other manufacturers via the ethernet interface.

GE Intelligent Platforms has announced the SBC622 rugged 6U OpenVPX-compliant single board computer. It is designed to play a key role in the field of network-centric warfare in programs such as Future Combat System (FCS) and Joint Tactical Radio System (JTRS), in which data driven architectures enable war fighters to gain a more complete realisation of the battlefield environment.

Typically challenging applications include early warning systems, command and control, and the aggregation, analysis and dissemination of real time sensor data including radar, sonar and video in air, sea and ground applications.

Integrated Controller

Rugged Single Board Computer

Enquiry no. 5905

Enquiry no. 5906

HMS Industrial Networks:

Invensys:

HMS Industrial Networks is extending its Anybus-CC family with the addition of a 2-port ethernet/ IP communication module with integrated switch. It provides interchangeable connectivity solutions for major fieldbus and industrial ethernet networks including Profibus, DeviceNet, CCLink, CANopen, Profinet, EtherCAT and Modbus-TCP. Anybus-CC modules are used as communication interfaces of intelligent automation devices such as drives, HMIs, robots, inverters, instruments, and scales. The two-port version allows ethernet/IP real-time communication with bus or ring topologies.

The module provides an easy way for any kind of automation device with an integrated Anybus-CC slot, to connect to any PLC with ethernet/IP support and eliminates the need for expensive external switches.

Invensys Operations Management has released its Wonderware Information Server version 4.0 software. Information Server is an easy-to-use software for web-based graphical visualisation, and the reporting and analysis of real-time plant operations data.

This version features support for ArchestrA graphics, necessary for customers who are using the Wonderware Systems Platform and InTouch HMI products; enhanced operating system support; and webbased graphics built on Microsoft Silverlight technology.

The software provides an interactive, open method of delivering critical operating information to workers engaged in manufacturing and industrial infrastructure processes. It is able to provide data in other forms compatible with corporate portals, such as Microsoft SharePoint.

Port Ethernet/IP Plug-In-Module

Enquiry no. 5907 60 industrial automation asia | August 2010

Information Server Software

Enquiry no. 5908

products & Services

Piab:

Rockwell Automation:

Piab has introduced its Pilnline range of inline vacuum ejectors based on Coax technology.

The products are suited for the packaging industry, where vacuum ejectors are required with good vacuum flows to enable reliable gripping, lifting and moving of objects.

The range tolerates fibres and dust and works well in applications for carton board and solid board materials that leak air significantly. The smallest model, the Micro, uses on the average, 50 percent less energy than comparable products. This means less energy consumption and lower carbon emissions.

Sound levels are also lower, which creates a better working environment.

The range comes in three sizes: Midi, Mini and Micro. Each size is available with a choice of three special options to enable optimised performance and capacity for the specific application.

Rockwell Automation ha s ex panded t he application development c a pa bili t ie s o f i t s F ac t o r yTa lk B a t ch software. The software features intelligent recipe capabilities, secure operator overrides, expanded data collection and reporting, and improved material management capabilities.

Integrated with the scalable PlantPAx Process Automation System, the software provides solutions ranging from small, basic sequencing to large, complex batch applications.

Intelligent Recipe Features – When defining a product, recipe authors can now reference system-wide data, such as previous ingredient feed-actuals or material properties, to simplify recipe development. The use of expressions based on this historical data rather than entering specific defined values allows the system to adjust run-time setpoints to accommodate variable batch activity.

Inline Vacuum Ejectors

Batch Software

Enquiry no. 5909

Enquiry no. 5910

Sick:

Siemens:

Sick has introduced the DWS510-Static combined volume measurement and weighing system. It is used for acquiring complete data (volume, weight and ID) on the consignments of courier, express and package service providers (CEP) as well as in logistics centres.

It is intended for low and medium throughputs of up to 500 units of freight per hour. At the press of a button it provides all the relevant data for freight calculations or for creating transport documentation. It consists of the VMS510 volume measurement system, a rugged static weighing system and a hand-held reading device for the code information – integrated in a stable mechanical structure.

Siemens PLM Software has launched the High Definition PLM (HD-PLM) technology framework. This enables decision makers throughout the product lifecycle to make better-informed decisions.

The framework unites users with the people, tools and precise product-related information that they need to intelligently evaluate decision alternatives.

The users’ experience – delivered through a variety of supported devices – will be personalised by actively placing them into the digital context appropriate to their role. HD-PLM will assist users in collaborative decision-making, and information will be clarified and turned into knowledge through an intuitive visual presentation.

Volume Measurement & Weighing System

Enquiry no. 5911

Technology Framework

Enquiry no. 5912 August 2010 | industrial automation asia 61

products & Services

STMicroelectronics:

Turck:

STMicroelectronics ha s announced the production availability of an analog-input 2x100W class-D power amplifier.

The TDA7498 is pin compatible with the TDA7492 2x50W amplifier as well as the 2x80W TDA7498L and 100W mono TDA7498MV. Pin compatibility between devices supports scalable product design using a common hardware platform to optimise development costs and time-to-market for new models. To simplify the development of multi-channel applications, the amplifier can also be externally synchronised, saving external components and avoiding cross-channel interference between channels. The amplifier uses BCD6S manufacturing technology, which allows analog, logic, and high-voltage functions to be built on a single chip.

Turck has introduced its Cat 5e Ethernet cables that are gigabit capable and incorporate flexlife cable jackets. This jacket material is resistant to abrasion, crushing forces and chemicals, making it particularly suitable for harsh duty environments.

The ethernet cables are available with four or eight conductors (two and four pair counts). The cables may be specified with straight or right-angle RJ45 or M12 connectors, accommodating diverse application requirements.

Class-D Amplifier

Ethernet Cables

Enquiry no. 5913

Enquiry no. 5914

Witte:

Yokogawa:

Witteâ&#x20AC;&#x2122;s Aluquick Solid workpiece fixturing system is suitable for large fixtures which require stability.

The system can be used to replace conventional heavy steel structures. A 50 percent weight saving can be achieved compared to similar structures in steel, which means that it facilitates handling and transport.

The systems comprises of extruded profiles with slots and is provided with a grid. This combination allows components to be positioned either repeatedly using the grid, or offset using the slot. Contrary to conventional slot profiles, the system ensures the repeatability of measuring fixtures as well as the further use of the individual profiles for other fixtures.

Yokogawa Electric Corporation has developed field wireless devices based on the ISA100.11a industrial wireless communications standard. These wireless products include an EJX-B series differential pressure and pressure transmitter, a YTA series temperature transmitter, and an integrated field wireless gateway for field sensor networks.

The ISA 100.11a standard presents the following advantages for use in industrial automation: 1. Reliability 2. Suitable for a range of applications 3. Improved flexibility and network expandability 4. Compatibility with existing wired systems

Fixturing System

Enquiry no. 5915 62â&#x20AC;&#x192; industrial automation asia | August 2010

ISA100.11a Field Wireless Devices

Enquiry no. 5916

products & Services Lab Equipment

Agilent Technologies:

Bio-Rad:

Agilent Technologies has released its Direct Drive Robot (DDR). The robot was designed from ground up to support today’s fast-paced and rapidly changing discovery environment. DDR provides benefits over belt and gear driven industrial robots that have been retrofitted for the lab. Direct drive technology has fewer moving parts for less wear-and-tear so they break down less often.

The robot has a lower inertia, making it a choice for lab settings where technicians interact with robots on a daily basis, and greater positional accuracy so that systems will have less downtime associated with re-teaching. The robot has other features including ‘one person, one touch’ teaching and a graphical software interface for easy configuration.

Bio-Rad’s TC10 automated cell counter accurately and reproducibly counts total mammalian cells within 30 seconds of slide insertion.

Auto-focus technology and image analysis algorithms eliminate the subjectivity of manual cell counting with a hemocytometer.

The TC10 automated cell counter offers a simple, rapid, and reproducible alternative to the hemocytometer. The system can also simultaneously determine cell viability using Trypan blue dye. An on-board dilution calculator automatically determines the volume adjustments necessary for cell concentrations desired in subsequent experiments.

Direct Drive Robot

Cell Counter

Enquiry no. 5917

Enquiry no. 5918

Porvair:

SP Scientific:

Designed to quickly and safely remove solvents from 96 or 384-well plates, the Ultravap Blowdown Station from Porvair Sciences is a versatile tool to optimise microplate sample preparation productivity.

The station achieves high sample throughput through advanced evaporator head technology and a manifold design, which directly injects heated nitrogen into each individual well of the microplate simultaneously. The system can remove most popular chromatography solvents in minutes.

For heat sensitive and thermally labile samples, the station may be operated in a two-stage mode combining rapid initial drydown with carefully controlled final solvent evaporation.

FTS Smart Freeze Dryer technology from SP Scientific is a control software tool to enable development scientists to accelerate and streamline the task of developing and optimising freeze drying cycles.

The technology enables the developer to generate the right cycle on the first attempt. It allows the scientist to create a streamlined but safe cycle that can shave days off the production cycle. This efficiency gain can eliminate production bottlenecks, expand capacity and reduce production costs.

Smart technology features a feedback loop that provides detailed data on the pharmaceutical product and the freeze-drying process – including product resistance, heat flow and product thickness.

Microplate Blowdown

Enquiry no. 5919

Freeze Dryer Technology

Enquiry no. 5920 August 2010 | industrial automation asia 63

EVENT PREVIEW

JEC Show Asia

2010

Strong economic expansion continues to spur composite developments in Asia, with significant growth in the major markets of China and India, as well as in the Middle East, Malaysia, Vietnam and Indonesia. The Asian production of composites looks set to more than double and reach 10 million metric tons by 2015.

T h e c u r re nt co mp o site s market amounts to more than €18 billion (US$26 billion) in Asia, and new application developments will remain a long-term growth 64 industrial automation asia | August 2010

driver for composites to replace other traditional materials in the global market.

“With the fast pace of growth being set in Asia, there is a strong demand for leading-edge composite applications across a broad spectrum of industries,” says JEC president and CEO, Frédérique Mutel.

The J EC Show A sia 2010 conference and exhibition, to be held on 12-14 October 2010 in Singapore, brings together the science, technology and business

of composites. This year, the event is expected to attract more than 300 exhibiting companies and 10,000 visitors. Last year’s exhibition attracted 7,000 trade visitors from 56 countries.

The show will focus on urban solutions in key application markets such as mass transportation, aeronautics, water solutions and environmentally friendly technologies.

According to JEC’s 2010 annual survey of the composites market, a major trend is the industrial shift from North America and Europe to Asia, particularly to China. It is estimated that China will account for 43 percent of the global composites growth by 2013, including 67 percent of the market growth in the building and construction sector.

And with China becoming the world’s largest automotive market in 2009, it is projected that the Chinese market will also make up 45 percent of the composites growth in the land transportation industry. At the same time, the Indian car market has been growing at an annual rate of 10 percent and is attracting the attention of many global vehicle manufacturers, which has in turn presented an opportunity for composites growth in India.

Composite materia ls a lso provide an advanced material choice for aerospace, wind energy, electronics and other growth industries in Asia-Pacific, such as pipes and tanks, offshore and waterfront solutions, sports and leisure applications.

Key industry players in the composites value chain will be present at the show, including major raw materials suppliers, semi-product and part processors.

Universities, R&D centres, and academies will participate, along with professional composites a ssociations from Australia, China, India, Japan, Malaysia, Taiwan and Thailand.

The event will also be supported by the scientific community and major institutions, including Agency for Science, Technology and Research, Singapore (A*STAR), National University of Singapore (NUS), Hanyang University (South Kore a), Sta nford Universit y (USA), Building and Construction Aut hor it y ( BCA), L a nd a nd Tra n sp or t Aut hor it y ( LTA), Singapore Tourism Board (STB), Economic Development Board (EDB), SPRING and Singapore Manufacturers’ Federation (SMa).

Process Automation Spotlight T he de m a nd for i mprove d manufacturing processes is set to grow across different market segments, especially for high value-added applications such as the aeronautics and wind energy sectors.

“While Europe currently has the highest rate of automation with 83 percent of processes being automated, compared to 68 percent in Asia, there is potential for manufacturers in the Asia Pacific region to leverage the innovative advantages of process automation to achieve cost reduction, improved productivity and higher product quality,” Mutel says.

JEC Show Asia will demonstrate au to m a t io n c a p a b i l it i e s i n manufacturing processes that involve composite materials, with 35 percent of the exhibitors expected to showcase equipment, machines and software solutions for advanced process automation.

Innovation Showcase The JEC Asia Innovation Awards program provides the platform to showcase and award prizes to leading composite solutions that create value in a range of different end-use sectors.

The selection criteria for the awards program are based on technical excellence, exemplarity

of the chain of partners, market potential, and originality. This year, the JEC Asia Innovation Awa rds w ill be ha nded out in the follow ing categorie s: aeronautics; automotive and mass transportation; defence and ballistics; construction and infrastructure; marine; wind energy; water solutions; space and telecommunications; and automation/processes.

End-user conferences and forums allow industry players to share their knowledge about the

latest technological innovations.

Application sectors will include aeronautics, automotive, land transportation, building and con st r uc t ion, w i nd e ne rg y, env ironment a nd rec ycling, natural fibres and biocomposites, marine, civ il engineering, automation and others.

October 12-14, 2010 Suntec Singapore ENQUIRY NO. 5921 August 2010 | industrial automation asia 65

Parting shot

Digester and Biogas Handling

Data Centre Dairy Cows

HP Labs By Manure Designs Data Centre Fuelled

Research demonstrates the ability to create a sustainable IT ecosystem using dairy farm waste

I

n a research paper presented at the A SME International Conference on Energ y Sustainability, HP researchers explained how a farm of 10,000 dairy cows could fulfill the power requirements of a 1-megawatt (MW) data centre – the equivalent of a medium-sized data centre – with power left over to support other needs on the farm.

In this process, the heat generated by the data centre can be used to increase the efficiency of the anaerobic digestion of animal waste. This results in the production of methane, which can be used to generate power for the data centre. This symbiotic relationship allows the waste problems faced by dairy farms and the energy demands of the modern data centre to be addressed in a sustainable manner.

Dairy farms and data centres may appear to be unexpected partners; however, HP Labs has shown that the specific needs and challenges of both can be aligned to create a sustainable life cycle, using technologies readily available today.

66 industrial automation asia | August 2010

Dairy Farm Operations • T he avera ge da ir y cow produces about 55 kg (120 pounds) of manure per day, and approximately 20 metric tonnes per year – roughly equivalent to the weight of four adult elephants.

• The manure that one dairy cow produces in a day can generate 3.0 kilowatt-hours (kWh) of electrical energy, which is enough to power television usage in three US households per day.

• A medium-sized dairy farm with 10,000 cows produces about 200,000 metric tonnes of manure per year.

Approximately 70 percent of the energy in the methane generated v ia anaerobic digestion could be used for data centre power and cooling, thus reducing the impact on natural resources.

Power Generation • Pollutants from unmanaged livestock waste degrade the environment and can lead to groundwater contamination and air pollution. Methane is 21 times more damaging to the environment than carbon dioxide, which means that in addition to being an inefficient use of energy, disposal of manure through flaring can result in steep greenhouse gas emission taxes.

• In addition to benefiting the environment, using manure to generate power for data centres could provide financial benefit to farmers. HP researchers estimate that dairy farmers would break even in costs within the first two years of using a system like this and then earn roughly US$2 million annually in revenue from selling waste-derived power to data centre customers.

ENQUIRY NO. 5922

Calendar of Events september 1 – 3 HVAC Asia 2010

Marina Bay Sands Singapore IIR Exhibitions Email: jennifer.chiah@iirx.com.sg Web: hvacrseries.com

13 – 15 Globaltronics

Sands Expo and Convention Centre Singapore Reed Exhibitions Web: www.globaltronics.com.sg

15 – 17 Industrial Automation Vietnam

Saigon Exhibition & Convention Centre Ho Chi Minh, Vietnam Hong Kong Exhibition Services Email: exhibit@hkesallworld.com Web: www.iavietnam.com

21 – 24 Automation 2010 Bombay Exhibition Centre Mumbai, India IED Communications Email: iedcommunications@vsnl.net Web: www.automation2010.in

22 – 25 VietnamPlas

SECC Ho Chi Minh City, Vietnam Chan Chao Email: steven@chanchao.com.tw Web: www.vietnamplas.com

22 – 25 Linkage Metalworking SECC Ho Chi Minh City, Vietnam Chan Chao Email: machine@chanchao.com.tw Web: www.linkagemtai.com

October 5 – 7 ProcessCEM Asia 2010

Sands Expo and Convention Centre Singapore ASPRI Email: processcem@aspri.com.sg Web: www.processcemasia.com

2010-2011

19 – 21 EP China 2010

China International Exhibition Center Beijing, China Adsale Exhibition Services Email: publicity@adsale.com.hk Web: www.epchinashow.com

25 – 28 CeMAT Asia

Shanghai New International Expo Centre Shanghai, China Deutsche Messe AG Email: carsten.fricke@messe.de Web: www.cemat-asia.com

27 – November 4 Singapore International Energy Week Suntec Singapore Singapore Singapore International Energy Week Email: ema_siew@ema.gov.sg Web: singapore.iew.com.sg

28 – 30 India Chem 2010

Bombay Exhibition Centre Mumbai, India Federation of Indian Chambers of Commerce & Industry Email: manojmehta@ficci.com Web: www.indiachem.in

28 – November 2 JIMTOF 2010 Tokyo Big Sight Tokyo, Japan JMTBA Email: jimtof@tokyo-bigsight.co.jp Web: www.jimtof.org

November 4 – 6 Autotek Indonesia 2010

Kintex Seoul, South Korea Korea Packaging Machinery Association Email: seoulpack@seoulpack.org Web: www.seoulpack.org

18 – 20 Drink Technology India 2010 Bombay Exhibition Centre Mumbai, India Messe Muenchen International India Email: info@drinktechnology-india.com Web: www.drinktec.com

22 - 25 Emballage 2010 – World Packaging Exhibition Paris Nord Villepinte Exhibition Centre Paris, France Comexposium Email: emballage@comexposium.com Web: en.emballageweb.com

24 – 27 Metalex Thailand 2010 BITEC Bangkok, Thailand Reed Tradex Email: Channipar.Vala@reedtradex.co.th Web: www.metalex.co.th

30 – December 3 OSEA 2010

Suntec Singapore Singapore Singapore Exhibition Services Email: amy@sesallworld.com Web: osea-asia.com

DECember

Jakarta International Expo Jakarta, Indonesia FireWorks Indonesia Email: info@asiafireworks.com Web: www.autotekindo.com

1 – 4 ProPak Indonesia Jakarta International Expo, Kemayoran Jakarta, Indonesia Pamerindo Indonesia Web: www.propakindonesia.com

9 – 13 CIIF Shanghai New International Expo Centre Shanghai, China National Development and Reform Commission Email: ciif@shanghaiexpogroup.com Web: www.ciif-expo.com

To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to:

16 – 19 Seoul Pack 2010

March 23 – 26 MTA 2011 Singapore Expo Singapore Singapore Exhibition Services Email: mta@sesallworld.com Web: www.mta-asia.com

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Visit Visit us atusGlobalTRONICS at GlobalTRONICS 20102010 Visit Visit Visit usVisit us atus GlobalTRONICS atus at GlobalTRONICS at GlobalTRONICS GlobalTRONICS 2010 2010 2010 2010 Booth Booth Number Number G12 G12 Booth Booth Booth Number Booth Number Number Number G12 G12 G12 G12 13 13 15 September 15 September 2010 2010 Visit us at GlobalTRONICS 2010 13 13 15 13 13 15 September 15 September 15 September September 2010 2010 2010 2010 Marina Marina BayBooth Bay Sands, Sands, Singapore Singapore Number G12 Marina Marina Marina Marina BayBay Sands, Bay Bay Sands, Sands, Sands, Singapore Singapore Singapore Singapore 13 - 15 September 2010 Marina Bay Sands, Singapore

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Founded Founded since since 1885 1885 in Japan, Japan, Oriental Oriental Motor Motor has has been been manufacturing manufacturing and and providing providing Founded since 1885 inin Japan, Oriental Motor has been manufacturing and providing Founded Founded Founded Founded since since since since 1885 1885 1885 1885 inmotors, in Japan, in Japan, inJapan, Japan, Oriental Oriental Oriental Oriental Motor Motor Motor Motor has has has been has been been been manufacturing manufacturing manufacturing manufacturing and and and providing and providing providing providing services services for electric for electric motors, motorized motorized actuators actuators and and fan fan motors motors to meet to meet the the needs needs services for electric motors, motorized actuators and fan motors toto meet the needs services services services services for for electric for electric for electric electric motors, motors, motors, motors, motorized motorized motorized motorized actuators actuators actuators actuators and and and fan and fan motors fan fan motors motors motors to to meet meet to meet meet the the needs the the needs needs needs of every of every industry. industry.

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For inquiries For fromfrom South South EastEast East Asia, Asia, India, India, Australia Australia andand and Forinquiries inquiries from Asia, India, Australia ForFor inquiries For inquiries For inquiries inquiries from from from South from South South East South East East Asia, East Asia, Asia, India, Asia, India, India, Australia India, Australia Australia Australia and and and and New New Zealand, Zealand, please please contact: contact: New Zealand, please contact: New New New Zealand, New Zealand, Zealand, Zealand, please please please please contact: contact: contact: contact: SINGAPORE ORIENTAL MOTOR PTE LTD

SINGAPORE SINGAPORE ORIENTAL ORIENTAL MOTOR MOTOR PTEPTE LTDLTD SINGAPORE SINGAPORE SINGAPORE SINGAPORE ORIENTAL ORIENTAL ORIENTAL ORIENTAL MOTOR MOTOR MOTOR MOTOR PTE PTE PTE LTD PTE LTD LTD LTD Tel: +65 +65 6745 Fax: +65 6745 9405 Tel: Tel: +65 6745 6745 7344 7344 Fax: Fax: +65 +65 6745 6745 9405 9405 Tel: Tel: Tel: +65 Tel: +65 +65 6745 +65 6745 6745 6745 7344 7344 7344 7344 Fax: Fax: Fax: +65 Fax: +65 +65 6745 +65 6745 6745 6745 9405 9405 9405 9405 sales@orientalmotor.com.sg sales@orientalmotor.com.sg sales@orientalmotor.com.sg sales@orientalmotor.com.sg sales@orientalmotor.com.sg sales@orientalmotor.com.sg sales@orientalmotor.com.sg http://www.orientalmotor.com.sg http://www.orientalmotor.com.sg http://www.orientalmotor.com.sg http://www.orientalmotor.com.sg http://www.orientalmotor.com.sg http://www.orientalmotor.com.sg http://www.orientalmotor.com.sg

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