IAA August 2012 by Eastern Trade Media

August 2012 IndustrialAutomationAsia

www.iaasiaonline.com

August 2012

MICA (P) 010/07/2012 | ISSN 0219/5615 | PPS 1561/06/2013 (022960)

SCADA: Collaboration

Reducing Fault By Measure | Safety Solutions | SCADA | Solar Panels & Systems

Medical Manufacturing Asia Vision Systems: Solar Power

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Reducing Fault By Measure

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ENQUIRY NO. 454

ENQUIRY NO. 458

contents august 2012

ISSUES & INSIGHTS

The Technology Behind A Man-Machine Interface

As more machines are integrated into factory automation and logistic automation processes, the need to ensure safe procedures of people working with machines heightens. Contributed by Derrick Ong, Sick

Process CONTROL

Utilising SCADA As A Collaboration Centre

SCADA Brings ‘real-time’ operations, maintenance and business information sources together in one integrated visualisation environment. By Eduard van Loenen and Frank Horden, Yokogawa

Case Study: SCADA For Cogeneration System

Choosing the right control system is an important process for long term success and profitability. RRB Sugar Mills, of India, explain their choice. By Larry Combs, InduSoft

Telemetry And Remote SCADA Solutions

Case Study: What If The Pipe Runs Dry?

Telemetry and remote SCADA solutions are becoming increasingly important as utilities have to manage expanding service areas. By William Hoo, Schneider Electric (Singapore) A redundant remote control and automation solution makes the water supply of the city of Luxembourg more reliable. By Oliver Götz and Andreas Neumann, Siemens

SOFTWARE & NETWORKS

Honeywell Shows Intuition

IAA spoke with Ashish Gaikwad, GM, business performance solutions, Honeywell Process Solutions, on the company’s new software platform ‘Intuition Executive’. By Mark Johnston

Instrumentation & Measurement

Memory Recorders For Testing

To monitor a commercial power supply or conduct a fault analysis on elevators, a device such as a memory recorder may be used. In this article, we will address the advantages of using this type of device over a more traditional oscilloscope. By Takashi Hama and Masanori Mita, Hioki E E Corporation 2 industrial automation asia | August 2012

ENQUIRY NO. 464

contents august 2012

SECTOR SPOTLIGHT

ENERGY

The Power Of Water

Hydropower is a means of generating electricity by the movement of water. The renewable energy sector has been increasing rapidly over the past several years, and is projected to continue strong growth into the future. By Andrew Lee

Vision Systems: Power Of The Sun

Responding to the global need for cleaner energy, vision technology is helping solar technology suppliers to ensure quality products and increase efficiency in the value chain. By Didier Lacroix, Cognex

Case Study: Solar Power In A Chip

In its US$600-million facility, Norwegian company Elkem Solar has embarked on industrialising the production of solar-grade silicon for solar power cells capable of generating renewable energy for more than 30 years. ABB delivered electrical high/ low voltage solutions to the total plant, including the System 800xA control solution. Contributed by Ablelom Mahari, ABB

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EVENTS

Medical Manufacturing Asia 2012

National Energy Efficiency Conference

Singapore International Water Week 2012

Renewable Energy Asia 2012

Regulars

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EDITOR’s PAGE

The Importance Of Measurement The knowledge we acquire from scientific exploration is only possible through measurement. Whether this be at the nanoscopic scale or the megascopic scale. At the heart of measurement are universally agreed upon standards, as there is nothing in nature that says an inch or a mile has to be a certain length, or that imperial measurement is better than metric. Measurement itself is the ratio of a physical quantity, such as length, time, and temperature, to a unit of measurement, such as the metre, second, or degree celsius. There are many standards bodies in the automation field related to safety, communication, networking, and so on. In safety, in particular, the standards protect operators from harm and ensure efficient working practices. In the field of renewable energy, particularly solar power, it is necessary to know how big the surface area needs to be in order to achieve the required electrical output. As not all solar cells are alike, some being more efficient than others and new technology being developed all the time, then the surface area required will vary as a result to achieve the same electrical output. In computer networking, TCP/IP is an important protocol stack and is key to how computers communicate with other computers across a network, such as the Internet. It provides a means to specify how data should be formatted, addressed, transmitted, routed, and received at the point of destination, and has four abstraction layers, namely the link layer, internet layer, transport layer, and application later. TCP/ IP is maintained by the Internet Engineering Task Force, which is the standards body for the Internet. There are many other standards bodies around the world, all focused on maintaining a ‘same page’ approach in their dedicated field, ensuring we all work with the same common data and achieve results that are recognised and useful internationally. In this issue of IAA we have articles on Safety Solutions, SCADA, System Migration, Modular System Architecture, Hydropower, and Solar Panels & Systems. We also have event previews from The National Energy Efficiency Conference 2012, and Medical Manufacturing Asia 2012 where we interview Dr Ricky Souw, chairman of Singapore Precision Engineering and Tooling Association (SPETA), who were co-organisers of the event. We also have event reviews from co-located events Singapore International Water Week 2012, World Cities Summit 2012, and CleanEnviro 2012, together with an event review of Renewable Energy Asia 2012.

Mark Johnston Assistant Editor

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Brenda Tan brenda@epl.com.sg Contributors

Derrick Ong, Eduard van Loenen, Frank Horden, William Hoo, Larry Combs, Oliver Götz, Andreas Neumann, Takashi Hama, Masanori Mita, Andrew Lee, Didier Lacroix, Ablelom Mahari, Augustine Quek Editorial Consultants

Jim Pinto Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

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6 industrial automation asia | August 2012

Smile to the Environment

Can Variable Speed Drive (VSD) contribute even more to cost reduction?

Fuji Electric, the pioneer in industry to develop general-purpose inverter since 1976 launches a new generation HVAC VSD. The FRENIC-HVAC is designed to optimize energy consumption in office and industrial buildings related to heating, ventilation and air conditioning which generally consumes 50% of the total electricity. Through active fine-tuning on water and air flow rates to achieve adequate pressure and temperature of Fans, Pumps and Blower, thus contribute in greater Energy Saving and Cost Reduction! The high performance enabled by the comprehensive use of Fuji Electricâ&#x20AC;&#x2122;s Technology opens up to greater possibilities with safe and easy maintenance nevertheless protects the environment.

FUJI ELECTRIC ASIA PACIFIC PTE LTD Tel: +65 6533 0014 I Fax: +65 6533 0021 I www.fujielectric.com I drive@fap.fujielectric.com ENQUIRY NO. 469

Industry News Environmental Biotechnologist And New York City Receive Lee Kuan Yew Prize Awards Singapore: Laureates of the Lee Kuan Yew World City Prize and the Lee Kuan Yew Water Prize took the stage at the Lee Kuan Yew Awards Ceremony & Banquet, held during the World Cities Summit, CleanEnviro Summit Singapore, and Singapore International Water Week. The awards honour outstanding contributions towards addressing global water and urban planning challenges. The ceremony was graced by Guest of Honour, Teo Chee Hean, deputy prime minister & coordinating minister for national security, & minister for home affairs, Singapore. Dutch environmental biotechnologist, Professor Mark van Loosdrecht, was awarded the Lee Kuan Yew Water Prize 2012 for introducing a paradigm shift in the understanding of the used water treatment process and for his significant contributions in creating sustainable solutions in the field of used water treatment. Chosen from over 61 nominations received from across 25

Lee Kuan Yew World City Prize exhibit

countries, Professor van Loosdrecht is the fifth recipient of the Lee Kuan Yew Water Prize. The Honourable Adrian Benepe, commissioner of parks and recreation, New York City, US, received the Lee Kuan Yew World City Prize on behalf of Mayor Michael Bloomberg for New York

City’s transformation after September 11, 2001. The biennial Lee Kuan Yew World City Prize honours outstanding contributions towards the creation of vibrant, liveable and sustainable urban communities around the world. The City of New York is the second Laureate named since the prize started in 2009.

The Big Three Predictions By Frost & Sullivan Singapore: Frost & Sullivan released its three big predictions for the industrial automation and process control market. Energy efficiency and sustainability, smart technologies and the influence from BRIC and other emerging economies will be the key topics in 2012 and beyond. Based on a survey of several hundred companies conducted in December 2011, this research paper highlights areas of growth. “Energy efficiency, advanced technology and geo-economics will transform the face of industrial automation in the future. Along with sustainability, these factors are set to influence product design, project cost and service capabilities of industrial automation vendors in the next-generation enterprise," comments Muthukumar Viswanathan, director for Automation and Process Control at Frost & Sullivan. The key themes outlined below feature heavily in Frost

8 industrial automation asia | August 2012

& Sullivan's industrial automation and process control research programme for 2012. A key driver for the research is the work Frost & Sullivan has been conducting around Mega Trends which are driving new and emerging market segments for key industry participants. Energy Efficiency And Sustainability: Sustainability, in terms of energy and resource efficiency, will be a key ingredient for the success of the global manufacturing industry. Smart Technologies: Factories of the future will be driven by megatrends such as cloud computing, cyber security and mobile and wireless communication technologies. BRIC And Other Emerging Economies: BRIC and other emerging economies across the globe are likely to sustain high growth in industrial automation markets.

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Industry News

Singapore: NXP Semiconductors has begun testing a next-generation congestion management system in Singapore. Cars equipped with the company’s 3.5G telematics solution Automotive Telematics On-board unit Platform (ATOP) are currently piloting modern mobility solutions in Singapore. Singapore’s infrastructure is the ideal testbed for intelligent traffic solutions as it faces the mobility challenges of today’s global megacities and aims to reduce pollution and congestion. During the Singapore trial, cars equipped with ATOP, a module allowing for costefficient and flexible integration into automotive electronics, will wirelessly collect real-time traffic data via 3.5G mobile broadband. This allows to test congestion management as well as secure payment, roadside assistance and paperless parking. “We are very pleased with the results of the Singapore trial so far as it proves that NXP technologies can help alleviate congestion and help manage peak-hour traffic, ultimately helping drivers to save costs and contribute to a greener environment. As a result of the success in Singapore, NXP is now working with governments around the world who are investing in new, smarter transportation systems,” explains Kin Wah Loh, executive VP of global sales and marketing and GM of NXP Semiconductors.

Mobility solutions picking up speed in Singapore

The ATOP module is the core of an On Board Unit (OBU). The OBU contains a GPS receiver that collects, with optimal privacy, real time data, such as the vehicle’s exact location, and wirelessly feeds it to a back office. This allows service centres to calculate the fastest and most cost-effective route or advise drivers to choose the best means of transportation. The NXP technology can also wirelessly communicate with other cars and traffic signs to warn drivers of dangers ahead and advise on optimum speed. 3.5G communication has the bandwidth to accommodate congestion management schemes as well as other services to improve the traffic flow and road safety. In a second step, these can be complemented with car-to-car and car-to-infrastructure communication

functionality. Such mobility concepts will allow people in global megacities like Singapore to optimally use and combine all means of transportation — including public transport, taxi, individual transport means and car sharing. A secure element is another key feature within this communication system. Financial-grade smart card technology allows for convenient and secure payment, regardless if public or individual transport. The company demonstrated advanced telematics functions at World Cities Summit 2012 in Singapore, from July 1-4, 2012. They showed electro mobility applications and use cases, as well as active safety and carto-car communication that can make traffic in megacities safer, smoother and cleaner.

MOU Between Yokohama City, Japan, PUB And Meidensha Singapore: Yokohama-city, Japan, PUB and Meidensha (parent company of MSL) have signed a MoU to collaborate on a used water treatment project using the anaerobic ammonium oxidising process. Meidensha will build a pilot plant at the Changi Water Reclamation Plant in Singapore. This joint research looks into the removal of high-concentration nitrogen by an anaerobic treatment method using anaerobic ammonia-oxidising bacteria. Meidensha already has a pilot plant in Yokohama,

10 industrial automation asia | August 2012

Japan with Yokohama-City. Undertaking similar research in Singapore allows Meidensha to better evaluate the system through a comparison of data collected from two sites with different conditions. Meiden will share the results obtained from these two plants, with an aim to improving and verifying the reliability of this treatment technology. Meiden exhibited at Singapore International Water Week 2012 , which was held from July 1-5, 2012, at Marina Bay Sands, Singapore.

Kevin Dowey, Sandbach, Cheshire, UK

NXP Enables Next-Generation Urban Mobility

Industry News

PUB Singapore And Meiden Singapore Collaborate To Treat And Recycle Industrial Used Water Singapore: PUB, Singapore’s national water agency and Meiden Singapore have signed an agreement to establish the first Ceramic Membrane MBR Demonstration Plant in Singapore to treat and recycle industrial used water in a more energy-efficient and cost-effective manner. MSL will also establish an R&D centre and assembly factory for ceramic membrane units in Singapore, as well as a facility for development, production and after-sales service in Asia. MSL will also be the regional headquarter for water business in Asia. The demonstration plant will be sited at the Jurong Water Reclamation Plant in Singapore and construction is expected to be complete by August 2013. The one year demonstration study will focus on process optimisation. The plant will be capable of treating one million gallon (ie: 4,550 cubic metres) of industrial used water per day. The reclamation of high COD industrial used water has conventionally been considered difficult. This project aims to demonstrate the effectiveness of Meiden’s used water processing system by combining the use of the Upflow Anaerobic Sludge Blanket (UASB) technology and Meiden’s Ceramic Membrane MBR system in achieving energy savings and a consistent high-quality output of recycled water. The use of UASB, a biological process, can remove COD efficiently while the Ceramic Membrane MBR, which has a longer lifespan than conventional membranes, can produce a stable water supply for recycling purposes. Together, they can potentially result in more energy and cost savings in the treatment of industrial used water.

This collaboration stems from an MOU signed in 2010, following which MSL has been conducting verification tests for the Ceramic Membrane MBR system in PUB’s Ulu Pandan Water Reclamation Plant. Following satisfactory test results from this test-bedding project, MSL is taking the research one step further by collaborating with PUB to construct a demonstration plant to reclaim industrial used water for recycling purposes. For this project, MSL will be supported under the TechPioneer scheme, which is administered by Singapore’s Environment and Water Industry Programme Office (EWI). The scheme aims to commercialise new technologies by encouraging early adoption of these technologies by both the public and private sectors in their operations, and promoting environmental sustainability at the same time. The scheme helps local companies in Singapore to build a track record for these new technologies and expedite the commercialisation of such technologies in the environment and water sector. Director of Cleantech at Singapore Economic Development Board, Goh Chee Kiong commented: “We are pleased that Meidensha has partnered with Singapore to develop, demonstrate and manufacture its cutting edge membrane technology. This affirms Singapore’s position as a living laboratory where companies can conveniently develop, trial and commercialise sustainable solutions. Meidensha can also take advantage of Singapore’s vibrant water industry ecosystem in conducting business activities across the value chain.”

Singapore: RS Components (RS), the trading brand of Electrocomponents, a distributor of electronics and maintenance products, has entered into a formal reseller agreement with Micrel, a manufacturer of Integrated Circuits (ICs) for analogue, Ethernet and high bandwidth applications. The agreement, which covers Asia Pacific, Europe, the Middle East, Africa (EMEA), marks the official engagement of RS as an authorised re-seller of Micrel products. As part of the agreement, the company has doubled its stock of Micrel devices

with the addition of more than 370 ICs to its semiconductor portfolio. The company was granted the status of authorised channel partner by Micrel as an acknowledgement of its sales performance in the EMEA region. This was endorsed last year with an award presented by Micrel to RS for its sales growth following a record 2010 during which the company’s sales of Micrel devices grew by 182 percent. The company’s global presence, including its infrastructure for the market in Asia Pacific, was also highly influential in

ldigital, UK

Micrel Recognises RS Components’ Sales Success With Formal Reseller Agreement

Micrel’s decision to formally appoint RS to its EMEA and Asia Pacific distribution network. August 2012 | industrial automation asia 11

Industry News

Ingredient Branding Program From Dow Water And Process Solutions Singapore: Dow Water & Process Solutions (DW&PS), a business unit of The Dow Chemical Company, has launched an ingredient branding program for DOW Filmtec Reverse Osmosis (RO) for residential water treatment systems. Recently, the company signed a Memorandum of Understanding (MoU) with a company in India, and companies in Russia and China signed ingredient branding agreements that enable them to highlight DW&PS RO technology in their home drinking water systems. “DOW Filmtec RO Inside provides Dow the platform to partner with

regional brand owners in the residential water treatment market and bring clean drinking water to consumer homes around the world — a subject of growing concern in many countries,” said Dr Wang Xiaolan, commercial director (Asia Pacific), DW&PS. There are a variety of home water filtration and purification technologies available in the market place. Of these, RO is among the most effective and widely used technology for rejecting contaminants, hardness and diseasecausing bacteria, cysts and viruses. “Not all reverse osmosis elements are created equal,” said Rajat Mehta,

associate marketing director, residential, DW&PS. He continued: “DOW Filmtec RO elements are one of the most widely used water purification technologies in the world. Every minute around the globe, Dow processes more than 57 million litres of high quality water.” Compared to other filtration technologies that rely on a screen or filter to remove particles, an RO system uses a membrane that can reject a high percentage of dissolved impurities that a screen or filter might let through. In fact, RO can take out virtually all contaminants and impurities, resulting in clean, safe and better tasting water.

Sembcorp Water Technology Prize Winners Unveiled During The Singapore International Water Week Singapore: The winners of the Sembcorp Water Technology Prize 2011/2012 were announced at the Young Water Professionals Networking Reception cum Award Presentation, held as part of the Singapore International Water Week (SIWW). An annual national competition sponsored by Sembcorp Industries and coorganised by Singapore’s national water agency PUB and Nanyang Technological University (NTU)’s Singapore Membrane Technology Centre (SMTC), this year’s competition saw 39 teams of students from secondary two to junior college build and run their own model NEWater plant. The winning team from Bukit Panjang Government High School, comprising Aloysius Ang Jian Feng, Sih Jason, Rachel Tai Yi Qing and Goh Zhi Yu, impressed the judges with their video presentation and efficiency of their NEWater plant design. All four students will receive a two-week internship with Sembcorp. The first and second runner-up teams came from Victoria School and Raffles Girls’ School respectively. Aimed at sharing knowledge about the NEWater treatment process and honing problem solving skills through experiential learning, this year’s participating teams visited the Sembcorp NEWater Plant and received workshop training by SMTC researchers over a period of 10 months. They subsequently assembled and ran a stimulated NEWater plant with the components given. Raffles Girls’ School student participant, Grace Sum, said: “The newfound knowledge we have picked up from

12 industrial automation asia | August 2012

this experience can be applied in various fields. We have learned a lot about the constraints and challenges faced by Singapore regarding water security and sustainability. Maybe in the future, when we become policy makers, we can apply this knowledge.” George Madhavan, director, 3P Network, Singapore’s national water agency PUB, said: “PUB is very encouraged by the high quality of entries that were submitted. Through this competition, we hope to increase awareness of water issues among the young, and inspire youths to think about innovative solutions to overcome our water challenges. For this year’s competition, students applied their creativity to produce videos and leveraged on social media to show Singaporeans and the world why NEWater is clean, safe to drink, and a pivotal solution to ensuring water sustainability.”

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Secure power solutions that deliver the performance you need. Products: Our complete catalogue of power solutions, featuring our leading brands such as APC™ by Schneider Electric and Gutor™, offers an unmatched range of single- and three-phase UPS units, rectifiers, inverter systems, active filters, and static transfer switches from 1 kVA to several MVAs. Services: Schneider Electric Critical Power & Cooling Services can proactively monitor and maintain the health of your systems, protecting your investments, reducing total cost of ownership and operating expenses, and providing peace of mind throughout the equipment life cycle. Solutions: Choosing the right combination of products and services from Schneider Electric gives you the convenience of a total solution – systems, software, and services from a single source.

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ENQUIRY NO. 467

Industry News

Singapore: Flagship Ecosystems Investment Private Limited (FESI), a Singaporean company, together with its local Bangladeshi partner established the first Centralised Effluent Treatment Plant in Bangladesh on a 30-year BuildOwn-Operate arrangement with BEPZA (the free trade zone authority in Bangladesh). It will receive effluent from all generating industries in Savar Dhaka Economic Processing Zone (DEPZ) at an approved service tariff rate and with guaranteed effluent volumes. The total investment of the project was S$10 million (US$7.92 million). The CETP started operations on February 1, 2012 treating an estimated 15,000 cu m/day of effluent to serve the collective needs of the more than 44 companies in the Old Zone of Savar DEPZ. The CETP will expand its capacity to 43,000 cu m/day within the next year to receive effluent from the 55 companies in the New Zone of Savar DEPZ. The effluent is treated to meet Bangladeshi Department of Environment (DoE) Regulations and discharged into the inland waterway. At present BEPZA has no plan to recycle the water. The CETP employs a newly developed Bio-Electric Process to treat the effluent. The first of its kind in

Zakir Hossain, Dhaka, Bangladesh

Singapore Builds First Central Effluent Treatment Plant In Dhaka

Kaptai Lake, Bangladesh

Bangladesh and a first in the world to utilise a Bio-Electric treatment profile on a co-mingled industrial wastewater stream. The plant possesses the best and latest combinations of technology and equipment provided and manufactured by Flagship Ecosystems.

MHI And PUB Sign MOU On Advanced Water Treatment And Recycling Technology Singapore: Mitsubishi Heavy Industries (MHI) and PUB, Singapore’s national water agency have signed a Memorandum of Understanding (MoU) to collaborate on the research and development of an integrated water infrastructure system for used water treatment and reclamation. MHI’s first initiative under the terms of the MoU will be a testbedding project at PUB’s Jurong Water Reclamation Plant. This test-bedding project will commence after the signing of the MoU with construction expected to be completed in the third quarter of 2013, followed by one-year trial and testing. MHI’s Singapore-based subsidiary — MHI Industrial Engineering & Services (MIES) — will build and operate the test-bedding plant. MIES will incorporate a total system using the company’s fullyintegrated water solutions technologies 14 industrial automation asia | August 2012

for industrial wastewater and water recycling to achieve high water recovery ratios over a long-term. MIES will identify variables that hinder the achievement of high recovery ratios. The highspeed sedimentation equipment and technologies will be utilised in the new plant to minimise plant space and maximise energy conservation. Takato Nishizawa, representative director and executive VP of Mitsubishi Heavy Industries, said: “We thank PUB for giving MHI the chance for the test bedding opportunity. MIES can offer effective measures to address the current challenges in used water reclamation. In this test-bedding plant, we intend to take in untreated industrial used water and target a higher recovery. Using the know how and technologies to be verified, we will develop and commercialise compact, high-performing and cost-

saving plants to achieve integrated water infrastructure systems that are suitable for smart communities all over the world.” Chew Men Leong, chief executive of PUB, said: “At PUB, we are constantly pushing the frontiers in water technology development and we are very happy to partner MHI on this project to optimise the efficiency of used water treatment. Together with industrial water solutions and intelligent water management systems, the water-wasteenergy nexus are three new research areas that we are focusing on to further grow Singapore’s water industry. We welcome water companies and research institutes to collaborate with us on novel research ideas and test-bed their new technologies and solutions in our facilities under actual site conditions.

Industry News

Singapore: Seagate Technology and DensBits Technologies (‘DensBits’) have announced a strategic agreement for the development of low-cost, high-performance Solid State Drives (‘SSD’) for the consumer and enterprise markets. In conjunction with the agreement, Seagate has made an undisclosed equity investment in DensBits. Seagate and DensBits are joining forces, to develop future products that are intended to provide customers with cost savings, high reliability, and greater performance. Under the agreement, DensBits’ Memory Modem controller technology will be integrated with Seagate’s various storage technologies to power a wide range of consumer and enterprise applications including 3 bits/cell (‘TLC’) 1Xnm Flash-based consumer grade SSD, and 2 bits/cell (‘MLC’) 1Xnm Flash-based enterprise-grade SSD. “Seagate is excited to be working with the talented DensBits team and believes we have a significant opportunity with our new strategic relationship to extend our leadership into the SSD market,” said Rocky Pimentel, Seagate chief sales and marketing officer.

Honeywell’s Industrial IT Solutions Group To Help Manufacturers Improve Cybersecurity Safeguards Singapore: Honeywell has announced the formation of the Industrial IT Solutions group, a global team of experts who can help manufacturers and process industry facilities protect against cyber threats. The Industrial IT Solutions group, part of Honeywell Process Solutions, specialises in the design, performance assessment and protection of networks used in the process industry, including wireless instrument and SCADA platforms. Its offerings will provide a range of vendor-neutral technology and services required to assess, remediate, maintain and manage plant automation network performance, vulnerabilities and cyber security measures. “Automation network security and performance has become a critical component of plant safety in the process industries,” said Jon Lippin, VP and general manager, Honeywell Lifecycle Solutions and Services for Honeywell Process Solutions. “As

Robert Linder, Springfield, MO, US

Seagate And Densbits Announce Strategic Agreement

control networks continue to expand and integrate to business systems, the risks and complexity of cyber vulnerabilities must be addressed with the same vigilance as process safety risks assessments,” he added.

Schneider Electric Powers Gardens By The Bay Singapore: Schneider Electric, has announced that the company has supplied and commissioned the 22KV Gas Insulated Switchgear (GIS) for Singapore’s iconic Gardens by the Bay project, located in Marina Bay. The 22KV GIS provide the primary electrical power supply for the whole installation, while secondary power supply are from the installation’s own embedded bio-waste generation plant.

The smaller footprint dimensions of GIS offer an attractive choice for spacechallenged installations, especially in Singapore. The company’s GIS equipment are widely used in Singapore and has a large installed base in utilities & power plants, O&G facilities, marine and offshore installations, industrial & commercial buildings, data centres, tunnels, airports, hospitals, hotels and many others.

www.facebook.com/IAAsia August 2012 | industrial automation asia 15

Industry News

ABB Electric Drives Save A Record 310 Million Megawatt Hours In 2011 “The future potential for energy and cost savings is enormous since only about 10 percent of industrial motors are combined currently with electric drives,” said Ulrich Spiesshofer, member of the group executive committee and head of ABB’s Discrete Automation and Motion division. “Using energy more efficiently will remain, for a significant time, the biggest opportunity available to cut energy consumption as well as costs and emissions,” he added.

Agilent Technologies Announces Availability Of Enhanced Calibration Certificate In Singapore California, US: Agilent Technologies has announced that it is offering an enhanced Certificate of Calibration in Singapore. The new certificate includes additional measurement information and provides a tighter linkage to international standards, such as ISO/IEC 17025:2005, for quality and metrology. This will give customers added confidence in the accuracy of their electronic equipment and improve audit readiness. The enhanced Agilent Certificate of Calibration includes: • Measurement uncertainty values at every data point to improve risk analysis, vendor comparison and confidence that products meet their design goals. • An easy-to-read traceability table that gives trained specialists the ability to focus on core activities, instead of collating audit reports and creating required traceability maps to the International System of Units. • A single report that includes a calibration certificate, traceability table and measurement data. The new certificate is available through Agilent Advantage Services, which provides calibration, repair and instrument management services to maximise the value of instruments over their lifetime. 16 industrial automation asia | August 2012

Claudio Jule, US

Zurich, Switzerland: ABB has released its annual estimate of the savings achieved by its installed base of drives. About 310 million Megawatt-hours (MWh) of electric energy was saved by the company’s drives in 2011, an increase of 19 percent compared with the previous year. Electric drives are used to regulate the speed and power consumption of electric motors. Industrial electric motors account for about 25 percent of all the electricity consumed worldwide. The savings from its drives in 2011 correspond to 260 million tonnes of CO2 emissions — had this power been generated by fossil fuels — or electricity costs savings of approximately US$34 billion for customers, at 2011 US electricity prices. These savings are equivalent to the electricity generated by around 41 nuclear reactors, or to the annual power consumption of 75 million EU households.

Zayo Announces Focus On Small Cell Colorado, US: Zayo Group has announced the formation of a dedicated team focused on ‘small cell’ and Fibre to the Tower (FTT) initiatives. The team will be reporting to Matt Erickson, president of Zayo Fiber Solutions. ‘Small cells’, which are smaller antennas that attach to lamp posts, buildings and other aspects of the urban landscape, are utilised to enhance the mobile network reach for wireless providers. ‘Small cell’ deployments require extensive fibre footprints to cost-effectively provide the infrastructure layer. The company currently manages fibre in more than 50 metro markets, and with the pending acquisition of AboveNet will enable other tier one markets such as New York, San Francisco and Houston. Already, the company provides the underlying infrastructure for 100 ‘small cell’ locations in three metropolitan markets. The company has appointed David Dunn, an experienced infrastructure executive to lead the efforts. Mr Dunn will lead the team committed to making its fibre footprint available for ‘small cell’ deployment and bring its ‘small cell’ offering to market.

Company Notice Effective from October 2008, Henson Vidoc no longer serves as a Hioki distributor. Hioki products are now available from Hioki Singapore, located at the following address: Hioki Singapore Pte Ltd 33 Ubi Ave 3 #03-02 Vertex Singapore 408868 Tel: +65 6634 7677 Fax: +65 6634 7477

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Industry Updates

Profinet, The Industrial Ethernet Based Fieldbus THE desire for standardised communication with only one network, extensive diagnostic capabilities, and network wide ser vice functions has led to increased adoption of Industrial Ethernet in Industry. Profibus International has developed a standard out of the experience gained from the long years of development of Profibus to adapt Industrial Ethernet to the special requirements of industry. The result is Profinet, a standard for open, manufacturer-neutral communication via Industrial Ethernet. Profinet meets all of the requirements for using Ethernet at all levels and in all applications of automation. That makes it very 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 line as well as ring structures. The integration of existing fieldbus systems and protection of investment is an essential part of Profinet. The device model on Profinet is based on the Profibus model, that means the I/O modules of the existing peripheral devices can still be used. 18â&#x20AC;&#x192; industrial automation asia | August 2012

Firewall, IT-Security Remote Access, VPN

(Redundant) ring directly with the PROFINET Devices

Line

Star Tree

Wireless communication (IWLAN) Fieldbus Integration

Many possibilities of network topologies with Industrial Ethernet/Profinet.

Fieldbus Integration

Integration of different existing fieldbus systems into a Profinet backbone.

T h e re a re d i f f e re n t I O controllers available which have both an Ethernet and a Profibus interface. Existing systems can therefore be easily integrated to the new Profinet environment. No big efforts are necessary on the user program and engineering system also a complete replacement of the Profibus device is not needed. Another possibility of integration is the proxy technology — for example, the IE/PB Link PN IO of Simatic Net — acts as a representative of the Profibus devices, this link is also available with a wireless LAN interface, this provides also new innovative possibilities to integrate Profibus with wireless technology into Profinet solutions. New Applications With Industrial Wireless LAN Solution Profinet is using the advantages of Ethernet technology so 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 integrated easily into the automation landscape even with safety technology. Ethernet In Real Time With Profinet The wide bandwidth allows Ethernet to be used in all tasks of automation, besides fast, cyclic IO communication (data transmission within 1ms), standard TCP/IP and IT protocols can be used at the same time on the same network. Profinet provides a reaction time of 1ms cyclic communication

PROFINET nodes 5 Mio.

> 4 Mio. 4 Mio. 3.0 Mio.

3 Mio.

2.1 Mio. 2 Mio.

1 Mio.

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

Last counting of the Profinet devices installed worldwide.

between the Profinet IO Controller and Profinet IO Devices. This mechanism works with standard switches. Cyclic communication is based on the OSI/ISO layer model on layer 2. That allows a fast reaction time on the Ethernet Networks. Profinet also provides a solution for high deterministic and fast motion control tasks. Profinet IRT — Isochrones Realtime, is used for fast automation tasks with a cyclic communication of 250µs and a jitter <1µs. In this case the network devices need an ASIC to guarantee the timing, the ASIC Siemens provides is called ERTEC (Enhanced Real-Time Ethernet Controller).

minimises the cabling costs and the number of different modules. Safety and standard data runs on the same wire. The Safety programs can be created with standard engineering tools ie: Simatic Step7 from Siemens. Customers will have new possibilities and advantages of using flexible Industrial Ethernet topologies including wireless technology in their applications. Besides that safety technology is also possible to use it on the same cable and on the same network. Profinet also provides scalable performance from very fast, high speed applications to regular IT applications, everything on the same network.

Profinet Is Fail-Safe Profisafe as an application profile is independent of the network technology; it can be used for Profibus as well as for Profinet Systems. The IO Slots in the Profinet-IO device can be mixed (Standard and Safety IOs), that

Profinet On The Rise With the latest counting released by the Profibus/Profinet International, Profinet reached the four million border of installed nodes worldwide. ENQUIRY NO. 5101 August 2012 | industrial automation asia 19

Newsdesk CAN Micro-Controller And System-Basis-Chips

Support Functional Safety The automotive industry adopts functional safety. Freescale (USA) supports this by its safe-assure solutions program. It highlights s o l u t i o n s — h a rd w a re a n d software — that are designed to support functional safety implementations compliant to ISO 26262 and IEC 65108. The chipmaker’s Qorivva MPC574 microcontroller family featuring three CAN interfaces and the MC33906 series of system-basischips (SBC) comprising CAN transceivers. The 32-bit microcontroller and SBC MC33906/7/8 help automotive systems meet all Automotive Safety Integrity Levels (ASIL) up to and including the most stringent one, ASIL D. Both chip families are designed from the ground up in a way that system manufacturers can more easily achieve system compliance with functional safety. The safe-assure program includes MCUs, sensors and analogue ICs, as well as support including training, safety documentation and technical support for functional safety application design. “Our system-level approach helps developers reduce the complexity of achieving compliance with safety standards while building advanced safety performance into their systems,” said Gavin Woods from Freescale. The Qorivva MPC574 microcontrollers provide the 20 industrial automation asia | August May 2009 2012

performance and features needed to address functional safety requirements up to the ASIL D level according to ISO 26262. Operating up to 180 MHz, the MCU is built on a 55-nm process with an integrated safety architecture, dual-core delayed lock step and additional on-chip redundancy. It can operate in extreme operating environments, such as electric power steering systems, that require a junction temperature of up to 165 deg C. By integrating many features into one safety platform, the MCU offers approximately twice the memory, performance and motor control capabilities of previous products from the chipmaker. Pin-compatibility means existing MCU customers can upgrade with only minor hardware and software changes. The SBC provide power to MCUs and other system loads and optimise energy consumption through low-power saving modes. The chip also contains CAN and LIN physical layers compliant with the ISO 11898-2/5 and LIN 2.1/ J2602-2 standards, safety measures and a serial peripheral interface to allow control and diagnostic with the MCU. The pin-compatible MC33906/7/8 family is the SBC solutions that includes DC/DC switching regulators to optimise energy efficiency. An optional boost

mode keeps the system available during engine cranking pulses. In addition, low-power modes reduce current consumption and optimise wake-up times. As with previous generations, the introduced SBCs are designed to meet the latest automotive OEM requirements for electromagnetic compatibility. The MC33906/7/8 chips are the first Freescale analogue solutions developed to satisfy ASIL D requirements. They include a range of integrated safety measures such as monitoring of critical analogue parameters, a fail safe state machine and an advanced watchdog. These features reduce s o f t w a re c o m p l e x i t y w h e n combined with dual-core lockstep MCUs. Development Support Support includes the MPC574xP Autosar safety MCAL and functional safety support documentation for these components, including a safety manual, safety application guide and an analysis of failure modes, effects and diagnostics. In addition, the chip maker works with third-party partners, who provide real-time operating systems, tool chains as well as training and certification support. Both products, MCU and SBC will available in the third quarter of 2012. ENQUIRY NO. 5102

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Fieldbus Foundation

Updates Technical Specifications For Remote Operations Management The Fieldbus Foundation, conducting a press briefing at Achema 2012 in Frankfurt, Germany, has an updated version of its Foundation technical specifications that is available for immediate implementation. This release addresses key elements of Foundation for Remote Operations Management (ROM) technology, which enables manufacturers to begin developing Foundation for ROM devices. Specifications have been added for transducer blocks for both wired and WirelessHART devices. The Solution T h e F i e l d b u s F o u n d a t i o n ’s Foundation for ROM solution offers a unified digital infrastructure for asset management in a wide range of remote applications, from oil and gas pipelines to tank farms and offshore platforms, and even OEM skid mounted equipment. The technology enables fieldbus connectivity to remote I/O and industrial wireless protocols, including WirelessHART and ISA100.11a. It provides an interface to these wireless technologies and uses Electronic Device Description Language (EDDL) and function blocks to ensure interoperability with Foundation for ROM devices. The Remote I/O (RIO) portion of the specification was released in April, 2011, and allows for connectivity of large point count remote I/O to Foundation fieldbus. 22 industrial automation asia | August 2012

The foundation has now launched the HART and WirelessHART specification for ROM. Foundation for ROM is the first example of the capability of integrating ISA 100.11a, Wi re l e s s H A RT, w i re d H a r t , and wired H1 protocols into a single standard environment, without sacrificing the diagnostic capabilities of the existing wireless devices. Those capabilities are mapped into the block structure to provide a standard environment for data management, quality, and more, eliminating today’s solutions which are highly customised and much more costly to maintain throughout the plant lifecycle. What Is Possible In addition, with Foundation for ROM, industrial operations can implement a true predictive and proactive maintenance strategy for remote assets that could not previously support one. Data from devices on multiple networks, both wired and wireless, are tightly integrated into the Foundation fieldbus infrastructure, providing a single environment for management of diagnostic data, alarms and alerts, data quality, control in the field capability, and object oriented block structure. Foundation fieldbus provides an all-digital communication i n f r a s t r u c t u re f o r p ro c e s s automation, with powerful m u l t i v a r i a b l e m e a s u re m e n t

capabilities, powerful device diagnostics, and the ability to integrate wireless devices across multiple networks. The block structure of Foundation fieldbus is unique, and provides true distributed functionality for implementing control in the field, improved data management, and alarm and alert management. The Architecture Within the Foundation automation architecture, the H1 (31.25 kbit/s) and HSE (100 Mbit/s) fieldbus networks provide a distributed function block capability with HSE serving as a larger pipeline with increased speed and throughput. The Foundation for ROM solution expands these capabilities by establishing open, non-proprietary specifications for an interface to wireless field device networks, a wired HSE backhaul, and a wireless HSE backhaul integrating various wireless sensor networks such as WiFi, satellite, cellular, and so on. As par t of this solution, Foundation for ROM provides a way to bring large concentrations of discrete and analogue field I/O back to the control room using HSE communication. This is key to improved integration of critical functional areas, including machiner y health monitoring, safety interlocks, fire & gas detection systems, and video surveillance. ENQUIRY NO. 5103

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The Tech United Team celebrates the first World Championship at the RoboCup 2012 in Mexico City.

EtherCAT Robots

Soccer World Championship

Win

THE EtherCAT enabled soccer robots of the Dutch Tech United team won the RoboCup World Championship of 2012 held in Mexico City. In a dramatic final the EtherCAT ‘Turtles’ beat the MRL team from Iran with 4-1. The Tech United robots compete in the middle size league, which is considered the league with the most sophisticated soccer robots. For Tech United from Eindhoven 24 industrial automation asia | August 2012

University this was the fifth RoboCup World Championship final in a row: since 2008 the team has managed to advance to the last game in each and every robot soccer world cup, but then finally lost against teams from Portugal, Germany and China. In spite of the clear result, the final match was thrilling. As usual, just before the game major software modifications took place. And the helpless feeling after uploading the

software was stronger this time than ever: images of the previous four finals flashed through the minds of each team member. Would it again go wrong in the last game of the tournament? But this time everything worked out fine: the ‘Turtles’ mastered the new rule best, which says that the robots may not dribble the ball over the mid field line — it has to be passed instead. Tech United has been the first robot soccer

The soccer robots carry an Embedded PC which controls the drives and all other functionality via EtherCAT.

The keeper is a special design with special software â&#x20AC;&#x201C; but he is also EtherCAT enabled.

The glorious Robot Soccer World Champions 2012: the EtherCAT enabled Tech United Team.

The current Turtles are already the 5th generation of soccer robots designed and built by the Tech United Team from Eindhoven, the Netherlands.

team ever to introduce the active passing of the ball into the game, at the German Open 2010. As such, the passes where sharp, exactly placed and many goal opportunities arose during the match. Another recent rule change was entirely in Mexican style: The Sombrero was introduced, a flat plate on top of the Turtles, which ensured to stop more lob balls. So correct passing, based on the precise communication between the robots was even more crucial. So this time the final was won, and the multiple European Robot Soccer Champion now also claimed the title of the Robot Soccer World Champion. The Middle Size League In the middle size league, two teams of up to five robots play soccer on

an 18x12 metre indoor field. Each robot is equipped with sensors and an on-board computer to analyse the current game situation and successfully play soccer. The dataacquisition and motion control of the Turtles relies on EtherCAT: sensors, actuators as well as the entire motion control loops take advantage of this ultra-high speed Industrial Ethernet technology. Through wireless c o m m u n i c a t i o n t h e ro b o t s establish cooperation and receive all referee commands. However: no external intervention by humans is allowed, except substitutions. So the robots play completely autonomously, including tactics, and cannot even be coached during the game. In recent years research in

the league made good progress. For example, some years back major parts of the soccer field were colour-marked in order to simplify orientation for the robots. Meanwhile the ball is the only item that is still colour-marked, goals may only be scored from the opponents half and passing over the midfield line is required. Regulation Change Changes in the tournaments regulation like this intend to eventually lead to the overall RoboCup goal: To develop a team of fully autonomous humanoid robots by the year 2050 that can win against the human world soccer champion team. ENQUIRY NO. 5104 August 2012 | industrial automation asiaâ&#x20AC;&#x192; 25

issues & insights

The Technology Behind A Man-Machine Interface O

ver the years, safety in the workplace has evolved r a p i d l y, f r o m d e t a i l e d safety procedures, to strict laws and acts to ensure that organisations comply with safety requirements. This evolution puts more responsibility onto the employers to provide a safe working environment for their employees. It is often said that more ‘safety’ results in lower productivity — the opposite is actually the case. Higher levels of safety result in increased motivation and

26 industrial automation asia | August 2012

satisfaction of the workers, and as a result higher productivity. So how does an organisation improve safety at their workplace? Part of the solution lies with making the machine safe so as to keep the human safe. In most cases of work accidents, fatigue or complacency are the biggest causes. It is therefore important to make the machine safe even under such circumstances. The requirements on the safety of machinery have changed rapidly with the increasing use of automation. In the past,

protection systems were mostly causes for inconveniences. For this reason they were often not used at all. Innovative technology has enabled protective devices to be integrated into the work process. As a result, they are no longer a hindrance for the operators. Instead they often even help productivity. For this reason, reliable protective devices integrated into the machines are essential today. The following steps will help an organisation to work towards a safer man-machine interface:

1 Risk Assessment When designing a machine or implementing a machine into a process, the possible risks shall be analysed and, where necessary, additional protective measures shall be taken to protect the operator from any hazards that may exist. To aid the employers with this task, the standards define and describe the process of risk assessment. A risk assessment is a sequence of logical steps that permit the systematic analysis and evaluation of risks. The machine shall be designed and built, taking into account the results of the risk assessment. Understanding how the human works with the machine in all aspects of operation and maintenance is also important. Where necessary, risk reduction follows a risk assessment by applying suitable protective measures. The repetition of the entire process, risk assessment and risk reduction, may be necessary to eliminate hazards as far as possible, and to sufficiently reduce the risks identified or in some cases, new risks that that are created out of the original risk reduction process. After the task of risk assessment, the next stage is to apply the risk reduction process.

• electrical equipment (electrical safety, EMC). • concepts for stopping during an emergency situation. • equipment involving fluids. • used materials and lubricants. • machine function and production processes. TK,PK,VKA4MY.pdf

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In any case all safety aspects with the use of suitable components are to be considered, and adapted such that in the event of a fault on the machine, the safety of people is paramount. The prevention of damage to the machine and the surroundings are also to be

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2 Safe Design Safe design (inherently safe design) is the first and most impor tant step in the risk reduction process. During this process, possible hazards are identified and avoided during the design stage. The desired safe design is integrated into the machine, and the interaction between the person at risk and the machine.

August 2012 | industrial automation asia 27

issues & insights

considered. All elements of the machine design are to be specified so that the functions are performed within the related limits allowed. 3 Technical Protective Measures Technical protective measures are necessary when the identified risks cannot be reduced by design measures. Technical protective measures can be realised by means of protective devices like safety switches or safety locking devices which monitors covers and doors, safety light curtains or safety laser scanners which protects the operators who are working very near to a hazardous point or monitoring the access into hazardous areas, or safety monitoring units to monitor the velocity and positions of automated robots and vehicles. The appropriate protective devices must be selected as part of the technical protective measure after identifying the safety tasks. Safety tasks are identified risk factors which need to be addressed.

The appropriate selection o f t h e p ro t e c t i v e d e v i c e s with the corresponding product technologies for the implementation of safety functions in a machine depends on the correct identification of the safety task. After identifying hazards and determining the safety functions with the protective devices, the next important step is to determine the level of safety necessary. The level of safety necessary is to be defined individually for each safety function and this also applies to all devices involved in the safety system, eg: • the sensor/the protective device. • the evaluating logic unit. • the actuator(s). By means of the application of standards, it is ensured that the effort for implementation is reasonable for the risk defined. The protection of an operator who manually inserts and removes parts at a metal press requires

different consideration when comparing to the protection of an operator who works on a machine on which the maximum risk is the trapping of a finger. The basis for all safety standards are the following parameters from the risk evaluation: • the severity of the possible injury/harm to the health. • the frequency and/or the duration of the exposure to the hazard. • the possibility of preventing the hazard. The combination of the parameters determines the safety level required. After which, the safety category level of the protective devices can be decided, taking into consideration, the structure of the control system, the reliability of the components used, the ability to detect failures as well as the resistance to multiple common causes failures in multiple channel control systems. In addition, further measures to avoid design faults are required.

Safety task:

Objective:

Safety protective devices:

Hazardous point protection with finger or hand protection.

Protect the operators working in close proximity to the hazardous point.

Safety light curtain, safety camera system.

The appropriate resolution of detection and safety distance between the protective device and the hazard point must be calculated carefully, so that upon detection of a dangerous access, the machine must stop before any harm is caused.

Access protection and hazardous area protection of a person (body)

Protects an operator when entering a hazardous area

Safety light curtain, safety laser scanner

A large area is protected with zone protection. Multiple directions access protection is possible with mirror columns.

Access protection with muting.

Protects access with ability to differentiate between persons and material.

Safety light curtain with muting functions, safety laser scanner with muting functions.

Very useful for machines with automated pallet loading. Cleverly designed to be smart enough to perform muting and entry/exit monitoring of human and material.

Hazardous area protection of a mobile application.

Protection of persons during movement of vehicles and prevention of collision.

Safety laser scanner.

A well integrated system of safety laser scanners can perform an all-round protection of the area around the mobile vehicle.

Examples of safety tasks and appropriate protective devices used for such tasks

28 industrial automation asia | August 2012

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issues & insights

• Have the consequences that could result from the usage of the machine in the noncommercial/non-industrial sector been adequately taken into account? • Is it ensured that the measures implemented do not excessively impair the correct function of the machine? 6 Putting The Machine Into Use Before the machine can be used, it is the responsibility of the employer to ensure that:

Safety devices used during a production process

4 User Information On Residual Risks If the safe design and technical protective measures are not completely effective, the user shall be warned about residual risks and informed about necessary suggestions. These include eg:

risk reduction is not achieved with a single technical protective measure, an adequate safety function result can be achieved in the overall assessment. Adequate risk reduction can be achieved if all the following questions can be answered positively:

• warnings in the operating instructions. • work instructions, training requirements or user familiarisation. • visible warning signs and pictograms. • notes for the use of personal protective equipment.

• Have all operating conditions in all phases of the life of the machine been taken into consideration? • H a v e t h e h a z a rd s b e e n eliminated or the risks associated with the hazards reduced as far practically feasible? • Is it ensured that the measures implemented will not result in new hazards? • Has the risk been appropriately reduced? Have the user’s been sufficiently informed and warned about the residual risks? • Is it ensured that the operators’ working conditions are not impaired by the protective measures taken? • Are the protective measures implemented compatible?

User information shall not be a replacement for safe design and technical protective measures. 5 Overall Validation Of The Machine As functional safety is only part of the risk reduction, it is necessary to evaluate all measures — that is design, technical and organisational — together in an overall validation. It is therefore possible in practice that, although 30 industrial automation asia | August 2012

• all safety functions have been implemented as practically feasible as possible. • all applicable safety standards have been taken into account. • the conformity to safety has been determined during the overall validation. • involve the ser vices of a professional safety services provider where necessary. This safety implementation must be included in the technical documentation. In Conclusion It is important as an employer to go through the mentioned steps and processes to ensure that the machine is safe. When machines are safe, the machine operators are safe. The results can be measured when seamless manmachine interface encourages improvement in productivity. Safe machines also help employers to avoid production downtime due to accident investigations, legal proceedings and unnecessary injury compensations. The investment into ensuring safe machine is definitely worth it in all aspect.

ENQUIRY NO. 5201

Service and Support Hotline

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siemens.com.sg/industry

process control

Utilising SCADA As A

Collaboration Centre T

he world of data collecting and monitoring is rapidly changing, driven by everincreasing competitive pressures to reduce/optimise the major OPEX cost factors. From a process automation point of view, this demands utilising new information technologies to deliver these cost savings. While these new technologies bring interesting improvements, each one requires more to learn and manage. A lot is expected from solutions that contribute to increased efficiency and reduction of waste and energy consumption. In applications where facilities are distributed over large geographical areas — sometimes in very severe climate conditions — a lot can be achieved by better utilisation of expertise and knowledge and a high level of automation to minimise human resources across 32 industrial automation asia | August 2012

local and remote production facilities. This will, at the same time, also contribute to waste and energy reductions in particular by establishing faster and better information sharing across domains of expertise to make well informed decisions in ‘real-time’. Most of such applications can be found in those related to the energy supply chain (ie: transport pipelines, oil and gas productions, terminals and renewable energy like wind and solar, and so on). A Decision Support Centre Significant contributions can be delivered by tailored collaboration environments, which can bring operational, maintenance and business information sources together in an integrated visualisation and data collection environment. This means that data from different sources needs to be

Jayanta Behera, Mumbai, Maharastra, India

SCADA brings ‘real-time’ operations, maintenance and business information sources together in one integrated visualisation environment. By Eduard van Loenen, business development manager, and Frank Horden, sales and marketing manager, Yokogawa

interrelated and translated into Key Performance Indicators (KPIs) of the most elementary operational and business functions. From these KPIs it must be possible to zoom in on the individual conditions and view their contribution and relation with the information and data they are derived from. A prerequisite to facilitate this integrated visualisation is a flexible and platform independent e n v i ro n m e n t t o b u i l d t h e applications for remote operations as well as being capable to integrate information from other sources ie: CCTV systems, websources (internet/intranet), internal documents. This integrated visualisation then needs to represent the information as naturally as possible. Fast deployment and development can be achieved by

standard components/elements that can build up the dashboard visualisation environment. The latest web-technologies are very powerful to bring these technologies to end users whether they engage at a central decision support centre or through a collaboration network of smart mobile devices (smartphones, tablet PC’s and so on).

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Collaboration Centres This concept is to a large extent in line with what is expected as delivering essential information from concurrent sophisticated management systems shared to specific enterprise groups by means of pre-defined reports. However the difference is in speed of information and interaction moving from a transactional process to ‘real-time’ interaction and intervention from a decision support or collaboration network acting as an enterprise information monitoring system. State-of-the-art collaboration centres can, in this way, facilitate a holistic view over all the key aspects of operations. Collaboration centres are utilised to overlook the grid network systems. The aim is to deliver enhanced and cross related information to show compliance and impact on environmental factors as well as to show impact on business performance factors. For instance, monitoring results in reduction of energy and waste represented as energy efficiency, carbon footprint/credits and direct cost savings. Furthermore collaboration centres should be able to provide more details on the issues that directly negatively impacts these key performance indicators. For instance, showing physical conditions of assets and their direct environment by means of integrated and easy to navigate and control web-cam views or local weather station sources that can

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Yokogawa’s Fast/Tools version R9.04 Web-based SCADA system

show and predict (animate) rain/ snowfall and temperatures from a couple hours or days ahead. Another important aspect is the contribution collaboration centres can deliver in optimising the efficiency of resources by facilitating the move from local to more centralised (remote) o p e r a t i o n s a n d ‘ re a l - t i m e ’ information sharing. The aim is to minimise human resources across local and remote production facilities and to centralise knowledge for more effective and consistent use. This is, of course, not limited to only an operational point of view but also applies to the maintainability of collaboration centres and pipeline management systems. The platform should preferably be the same for both and support centralised engineering, deployment, license and revision management as well. SCADA, in these applications, already holds a key role in the collection of field information and exchange of data with other application and/or enterprise systems. Therefore, control and management systems that incorporate the latest web-based and platform independent IT technologies can be most effectively utilised as a collaboration centre platform. 34 industrial automation asia | August 2012

Fit-For-Purpose Solutions Yokogawa’s Fast/Tools version R9.04 Web-based SCADA system provides users a method for remote engineering and maintenance, deploying process applications and real-time management of these via secure web-based services, therefore increasing Overall Equipment Effectiveness (OEE) and Return On Assets (ROA). Combining the systems that businesses already rely on with the latest technology solutions, this web-enabled software, allows those businesses to secure previously made investments. With the proliferation of our decision support and collaboration centres, data from a variety of sources can now be accessed and shared globally, allowing continuous application development and management. Functions to facilitate these requirements are available with these new supported technologies. This will increase management efficiency through the continuous availability of process and maintenance information from all sources with an expected reduction in cycle time and a reduction in the need for the exchange of paper documents. As mentioned, this requires special applications to go beyond traditional HMI/SCADA

related environments. The saying that pictures say more than a thousand words drove the development of the real-time operation recording facility. Functioning much like a flight recorder, this enables the synchronised playback of screens with alarms and events as well as process and trend data, and includes all mouse tracks and relevant keyboard strokes. The recorded video data can be used for cause-and-effect analysis, operator training, and simulation to increase overall safety, security, and regulatory compliance. This adds a significant new dimension to the capabilities of this software, which already includes audit trailing and diagnostics functions. As an addition to its standard EEUMA 191 compliant alarm management functionality, this software also enables alarm notification messages to be emailed to certain subscribed users per specified areas and destinations. This call-out function makes it easy to define when, where and to whom notifications should be sent. The alarm management function now also enables the export of alarm & event notifications to programs such as MS-Excel for alarm analysis. Of course a web-based server and client architecture requires easy remote access, but also deployment of security enhancements in compliance with company security policies and in accordance with corporate IT directives. To enhance and incorporate security, this system and its applications are hardened to protect against failures and prevent unauthorised access and use. At the same time, simple licensing policy can make it easier than ever to reduce costs through web-based engineering and virtualisation. ENQUIRY NO. 5301

process control

Case Study:

SCADA For

Anderson Carvalho, São Paulo, Brazil

Cogeneration System

Choosing the right control system is an important process for long term success and profitability. RRB Sugar Mills, of India, explain their choice. By Larry Combs, VP of customer service and support, Indusoft

RB Sugar Mills is one of India’s largest sugar producers, with a capacity of 400 Tonnes of Cane per Day (TCD). While most industries rely on external power sources to fuel their operation, sugar manufacturers can produce their own power in a process called cogeneration. As part of the process to produce sugar from sugarcane, by-products such as bagasse — a left-over fibre that results from the crushing and extraction process — can be employed as an eco-friendly fuel for power cogeneration. The bagasse can be incinerated to fuel a boiler furnace, which then can be used to produce electricity. The power, produced by the furnace

RRB Sugar Mills selected an Indusoft web studio-based HMI/SCADA system.

August 2012 | industrial automation asia 35

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can be used in the production of more sugarcane â&#x20AC;&#x201D; a net positive energy gain. Historically, sugar mills in India were permitted to produce only the energy they needed for their own operations. Most Indian sugar companies therefore adopted the practice of installing inexpensive boilers and turbines, which were notoriously inefficient. They typically would operate only during the sugar season. With the power generating restriction there was no incentive to invest money in an expensive, efficient system when very little opportunity exists for a return on that investment. Cane Sugar Combats The High Price Of Crude Oil Like nearly every country, India needed to reduce its energy costs. To reduce its dependence on expensive crude oil, cane sugar started becoming recognised as a valuable commodity in the form of energy-rich ethanol. In the mid-1990s, the Indian Ministry of Power began permitting companies to generate surplus energy. The energy could then be exported to the state electricity board or to other manufacturers. This in turn subsidises production costs, promotes competition, and makes electricity more plentiful for everyone. When exportation of energy was permitted, many plants, including RRB Sugar Mills, began looking for ways to increase the efficiency of their power plants. At its Wategaon, India, facility, RRB installed back pressure turboalternators with two high-pressure boilers, a turbine generator and a backpressure turbine generator. This required a new control system. Although the system was initially installed only to control the boilers, it worked so well that RRB expanded it to also control the entire sugar-making and wastewater processes. 36â&#x20AC;&#x192; industrial automation asia | August 2012

With a single glance an operator can assess the entire boiler system â&#x20AC;&#x201D; a vital safety consideration.

Schematic of Boiler Feeder.

Advanced Boiler System Project managers at RRB knew they needed a systems integrator to develop and implement the automation and control system, and they turned to Control and Solutions India Limited (CSIL). CSIL was chosen because they specialise in automation and control systems for the process

industries, building automation, and substation automation. The boiler control has many useful features that have made the process much more manageable. For example, it reads boiler process parameters from primary sensors and secondary instruments, which helps RRB control critical points in the process. The system also

Selecting The Right HMI/SCADA For The Cogeneration System After reviewing the existing cogeneration system, CSIL provided RRB several options for a centralised system that would meet its requirements. Ultimately, RRB selected an InduSoft Web Studiobased HMI/SCADA system with Honeywell PID loop controllers. D e s i g n e d f o r M i c ro s o f t Windows environments, InduSoft Web Studio uses open technologies to connect to monitoring and control hardware and third-party software applications. The PID controllers implemented are based on open technology and were easily networked to the InduSoftbased system that includes more than 240 native drivers. To m o n i t o r t h e b o i l e r t e m p e r a t u re , t e m p e r a t u re scanners were easily integrated into the company’s system through a Modbus communication driver. The application collects temperature data from these scanners, displays temperature values on colour graphic screens, and logs the data where it can be used to generate graphs. CSIL and RRB engineers developed the HMI/SCADA applications, which included control algorithms, alarm and reporting systems, and data logging functions. This full-featured, performance management system was developed and implemented using the company’s Web Studio’s menu-based Rapid Application Configuration Environment (RACE). The InduSoft-based system presents real-time data from the boilers and turbines

to the analysing logic, and then downloads appropriate set-point changes to the PID controllers. With the company’s Web Studio, RRB Sugar Mills can evaluate system ef ficiency, reducing the per-unit generation cost. By implementing the new cogeneration system controlled

by PID controllers and the company’s Web Studio HMI/ SCADA system, RRB now only produces quality sugar, but also is able to generate power to help India’s growing manufacturing and infrastructure needs. ENQUIRY NO. 5302

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controls threshold deviations and activates alarms if thresholds are breached. History data logging is built into the system and a browsing feature provides access to the logs for a complete history of the operation.

August 2012 | industrial automation asia 37 DensoRoboticArmAd.indd 1

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process control

Telemetry and remote SCADA solutions are becoming increasingly important as utilities have to manage expanding service areas. By William Hoo, VP, Industry Business Unit, Schneider Electric (Singapore)

Nick Lobeck, Zürich, Switzerland

Telemetry And Remote SCADA Solutions

upervisory Control And Data Acquisition (SCADA) systems have greatly evolved over time, beginning with simple tone telemetry to the modern webbased solutions of today. SCADA systems have typically been used in a reactive manner to identify problems as they occurred, and record system data and events. But today, with a greater premium placed on productivity, SCADA systems have to evolve into proactive ones, supporting extensive data management and security capabilities, in order to prevent problems from happening in the first place. At the same time, SCADA systems have to also address some of the more pressing needs of utilities today. Due to population growth, utilities have to manage expanding service areas, some of which may be located in remote

38 industrial automation asia | August 2012

places which are hard to access. As a result, some of the following challenges arise: • Cost Concerns The challenge of monitoring remote assets is that it can get expensive to set up and maintain operations. If communication lines have to be laid in order to monitor remote facilities, it could potentially involve hundreds of thousands of kilometres of cable, amounting to huge setup costs. • Security This is another huge concern for utilities everywhere, as m a n a g i n g re m o t e a s s e t s necessitates the transmission of data from field to base station, and perhaps through multiple points in the network.

As modern-day systems are typically connected to the TCP/IP networks, corporate networks and/or the Internet, each network node represents a potential vulnerability in the system if malicious third parties are able to bypass the security systems and obtain access to sensitive data. • Regulatory Requirements At a federal level, governments are also becoming increasingly stringent on utilities, requiring them to constantly adhere to stricter security, environmental and compliance measures set out by regulatory bodies, as well as ensuring the overall safety of assets. • Integration In order for utilities to meet efficiency and productivity

The Solution In response to the market demand, the company, Schneider Electric, developed a solution known as the Telemetry and Remote SCADA Solution (TRSS). TRSS incorporates the SCADAPack Smart RTU, a programmable field controller designed for the monitoring and control of remote assets. One of the main aims of the TRSS solution is to reduce the operational costs for their remote sites. This is because such operations are commonly spread across a wide area with equipment being exposed to harsh environments, making operation and maintenance of these systems often the most significant overall expense factor in the long term. The Importance Of Security With security always a concern on the minds of utilities, SCADA systems which monitor missioncritical infrastructures need to be resistant to cyber attacks and natural disasters, intercepting any malicious attacks or attempts at sabotage. At the same time, data needs to be delivered securely and without loss, as constant data availability is critical for monitoring. The TRSS contains several features which help protect the data being transmitted from the remote site, such as one which stores a timestamped event in the data queue, enabling the SCADA host to obtain a continuous record of data history even when communication links go down. Customer Benefit In December 2011, one of the

water works installations in Singapore implemented the TRSS wireless solution in partnership with a system integrator. The telemetry system included the use of Trio K series wireless modems operating on the 2.4 Ghz spectrum. These modems were set up in

clusters, with distances sometimes exceeding 800 metres between two stations. The project saved several hundreds of thousands of dollars which would have been required for installation of cables over several kilometres. ENQUIRY NO. 5303

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August 2012 | industrial automation asia 39

Case Study:

The Pipe Runs Dry? What If T

he city of Luxembourg waterworks were looking for an automation system that would ensure a high quality and reliable water supply â&#x20AC;&#x201D; and they found it. The solution: A redundant, dedicatedline system in combination with a continuous remote-control system that transfers data along two different paths. Many cities have to pump their drinking water over distances of hundreds of kilometres. This is not the case for the city of Luxembourg. Here ultra pure spring water bubbles from the Luxembourg sandstone at numerous locations. The 72 springs can supply the city with as much as 60 percent of its water requirement. The waterworks buy the remaining 40 percent from a reservoir that belongs to the Sebes 40â&#x20AC;&#x192; industrial automation asia | August 2012

A redundant remote control and automation solution makes the water supply of the city of Luxembourg more reliable. By Oliver GĂśtz and Andreas Neumann, presales support, Siemens

Dave Millet, Portales, New Mexico, US

process control

syndicate. There is one more special feature: The service of the Eaux de la Ville de Luxembourg and its staff of 66 supply drinking water to not only the 92,000 inhabitants but, during the week, also to around 140,000 daily commuters from France, Belgium and Germany. Six pump stations, twelve elevated tanks and two water towers are used to maintain adequate line pressure along the 400 kilometres of pipeline from the former fortress town and across great differences in elevation that prevail along stretches of this pipeline. The Importance Of Redundancy In 2009, the city of Luxembourg waterworks decided to bring their entire water supply system up to

Tonnar, the engineer in charge of technology at the waterworks. Various solutions were proposed and their advantages and drawbacks were discussed in detail. There was one thing, however, that everyone could agree on: The higher level automation system would have to be flexible, open-ended and an industrial standard. Siemens was able to meet these requirements. “Everyone in the Siemens world is familiar with step seven. However, there were only two external experts who could program step seven in the old system. We did not want to find ourselves this dependent again,” explains Mr Tonnar. The System A standard automation system based on the Simatic WinCC process visualisation system was selected. The Supervisory Control and Data Acquisition (SCADA) system is technology and industry neutral in design, modular in structure, extendable, completely scalable, and is also suited for distributed systems. Although WinCC is essentially an ‘off the peg’ system, the city of Luxembourg has customised the

ENQUIRY NO. 444

date. A new automation and remote-control system was to be implemented to ensure an efficient and reliable control and monitoring of the entire water supply, including all remote terminals. The most important requirement for the new system: Reliability. “The main reason for the modernisation was that redundancy was required,” explains Nico Pundel, director of the waterworks. He continued: “In the old system it would have been very expensive to implement redundancy and we would still have been left with outdated technology.” Redundancy is of crucial importance to the waterworks, not least for reasons of economic efficiency, especially as there is a limit to the amount of water that can be drawn from Sebes. If the city requires more, it has to pay a contract penalty to the municipal authority. Consequently, the city of Luxembourg uses a special higher-level program that intervenes in the control system and regulates the various pump stations, tanks and water towers accordingly. “If the program fails, especially during the hot summer months, things can get really expensive for us very fast,” explains Yves

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August 2012 | industrial automation asia 41

process control

Figure 1: The piping in the Bridal‘s largest water tank with a capacity of 750sqm.

process visualisation system to its own special needs. The competence team from Siemens Mannheim supported the city in this. One special feature of the system, for example, is a simple and consistent colour designation in the visualisation system, which is also reflected in the local stations and tanks (Figure 1) or the clear representation of measured values for determining the water quality. Colour coded limit ranges show at a glance whether a measured value is ‘in the green range’ or requires re-adjustment in the process. Measured values can also be simulated; in other words, fed directly in the control system using I&C. This type of simulation is useful if a measured value fails and no measured value is then signaled to the system. For the system, a missing measured value is a faulty measured value. For safety reasons, the drinking water is then ‘destroyed’. Measured values can be simulated, for example, to ensure that high quality water is not directed back into the stream as wastewater. In addition, a Higher Level Designation system (HID code) is implemented, ie: a cross-industry coding of plants, plant segments and equipment for uniform and system coding. Encoded in this system, for instance, is the exact topographical location of a gate valve or other device in the entire system. The code can be switched on or off in order not to overload the visualisation screen. Just In Case Sinaut ST7, which belongs to the TeleControl Professional range of products, will be used as the preferred remote-control system. The system, which is based on Simatic S7, monitors and controls remote process stations fully automatically. 42 industrial automation asia | August 2012

Figure 2: A special water usage optimisation program ensures that the giant water tower in the Kaltreis district is filled to under the edge on the hottest days of the year.

The highest level of reliability was required here too. “Previously, we had only one server and would have had a real problem if this had failed. Added to this was the fact that we had only one wire connection. If an excavator had hit this, the whole system would have been incapacitated,” the engineer explains. Today, the city of Luxembourg waterworks has two servers, which are situated at different locations – and as such also two remote-control stations. One of the control stations hereby manages the process. All the functions are also active in the second control station, but no control commands or setpoint values are transferred to the substations. If one control station fails the other one is activated without any interruption. Each control station is equipped with two Simatic S7-400 controllers; the remote terminals each operate with one Simatic S7-300 controller. The data connections between control station and remote terminals are also redundant in design — first via General Packet Radio Service (GPRS) and second via a dedicated line. Each of 17 substations allows a continuous process data communication with the two central control stations, as well as a crosscommunication with each other. Possibilities Of Remote Control Technology WinCC system’s Web Navigator in conjunction with the TeleControl Professional remote control system allow systems to be controlled and monitored via the Internet from any location. “Theoretically, you can do everything from at home,” says Mr Tonnar. He continued: “In actual practice, of course, there are various users with various authorisations.” The system offers other benefits as well: The

Fit For The Future Thanks to modern communication technologies, fault messages are also sent automatically today. If a fault occurs at the weekend, for example, the Siemens Alarm Control Centre automatically sends an SMS which has to be acknowledged within a specified period. True to the motto ‘Two are better than one’, the waterworks does not want to rely on a single system here either. The already installed communication modules, whose functions also include an SMS alarm signaling, offer an elegant and cost-effective solution to the problem. “We are planning to implement this additional safeguard in the near future. The SMS messages will then be sent twice, once at the top level from the control system and once at the bottom level from the substation. If we then also use two different providers, we are certain to be on the safe side,” according to Mr Tonnar. Mr Pundel has the following to add: “When this solution is in place we can eliminate almost all the weekend shifts.” Staff that are on duty at the weekend in particular can simply dial in from their laptops at home and check at regular intervals whether everything is OK. Ideas for additional program modules are already starting to take shape in the minds of the Luxembourg waterworks specialists. Planned, for example, is a maintenance program for the pumps, whereby maintenance and repair of equipment such as pumps and motors can be planned and carried out in advance. This is expected to prevent uncontrolled machine downtimes in future. Another idea is to make the water hardness

measurement data available online to provide citizens with even more information about the service and further increase their confidence in the quality of Luxembourg’s drinking water. ENQUIRY NO. 5304

The Remote-Control Technology In Detail Systems For The Substations • Simatic S7-300 controller • Simatic MP 377 Touch Multipanel • Sinaut TIM 3V-IE Advanced communication modules • Sinaut MD741 GPRS modem • Sinaut MD2 dedicated-line modem Systems For The Control Station • Simatic WinCC • Sinaut ST7cc control station software for the connection to WinCC • Simatic S7-400 controller • Sinaut TIM 4R-IE master communication module • Sinaut MD2 dedicated-line modem • Scalance X204-2 ENQUIRY NO. 5305 • Scalance S612

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engineer can even control the entire system using his smartphone. The consistent remote control system allows not only a comfortable monitoring and control of the entire water supply, but also saves substantial travel times and numerous local deployments. Mr Tonnar confirms this as well: “Before, I was to spend up to half of my working hours in the car and at the pump stations. The furthest station is around 20 kilometres away. Today, I do not spend more than five to 10 percent of my time there. We have never calculated what the precise savings are, but the new solution saves a lot of time and therefore a lot of money.” The city’s citizens have already noticed the benefits in their wallets. The new system allows the waterworks to offer their customers the valuable water at an extremely moderate price. “The key factor is that the redundancy provides a double safeguard and a high level of reliability for our water supply,” the director emphasises.

August 2012 | industrial automation asia 43

software & Networks

Honeywell Shows Intuition IAA spoke with Ashish Gaikwad, GM, business performance solutions, Honeywell Process Solutions, on the company’s new software platform ‘Intuition Executive’. By Mark Johnston

ntuition is the family name of different software products and applications that Honeywell is preparing to bring out in the near future. Intuition Executive is the first product, in this family, that is being released onto the market. IAA spoke with Ashish Gaikwad, from Honeywell Process Solutions to learn more. IAA: How did the Intuition family come about? Ashish Gaikwad (AG): As you probably know Honeywell acquired a company by the name of ‘Matrikon’ in 2010, which had started working on a future generation platform for providing very process industry specific Manufacturing Execution Solutions (MES). Having acquired the company and therefore the technology, Honeywell invested further into this platform. We got a lot of advice from our customers since the main customer base for Honeywell Process Solutions comes from the process industry, such as, Oil & Gas, Refining, Petrochemical, Minerals, Metals, Mining, Pulp & Paper, and so on. One of the challenges that the customers had was to make good use of the data overload that has been happening for the past few years, such as, customers could collect many bytes of data and have to store it and using it was a problem, so that got done over a period of time. Heterogeneous 44 industrial automation asia | August 2012

systems exist in each of the process plants that we go to, some of them are older, some of them are of a newer generation. The challenge also was how do you make sure those are orchasted properly at a certain layer of abstraction where that layer is agnostic as to whether it is an old system or a new system or if it is from the same vendor or not. One of the key advantages of the Matrikon technology brought to the Honeywell family was vendor neutrality, because they as a stand alone company used to deal with all kinds of systems and that is a very important aspect that we bring into this platform where it becomes agnostic to the distributed control systems that is underneath. Also, it becomes agnostic to the applications that have been invested in the past. So, I think we are trying to solve two or three key things for our customers. IAA: What are you trying to solve with this platform? AG: One is maintaining and protecting the investments that we have already made over the last decade. We are trying to make sense out of the vast amount of data that has been collected, historically as well as on a day-to-day basis. What the senior executives in the customer organisations are asking is, ‘we have the data, and we can see that the trends are nice and so on, but how do I therefore make my workforce

IAA: What key themes run through the Intuition family? AG: We have three specific key themes: anticipate, collaborate, and act. Anticipation is making sure that you collect the data and then making sense of that data. They key is that we make the data very contextualised, so that the same data when viewed by an operator takes the right actions, and the same data when viewed by the maintenance people; they take the right actions, and so on. A team is also about collaborating, and making the whole system action originated, so it does not just remain in the heads of people or on a spread sheet, but the correct signals reach the correct people and if the appropriate action is not taken then there is the ability to escalate to a line manager or again to the plant manager. These are some of the main themes of Intuition Executive. ENQUIRY NO. 5401

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actionable so that they take the appropriate actions based on that data. How do I therefore make the whole system and the investment that we have made intelligent enough so that they point the operators to the right direction rather than they trying to figure out what is the best action out of that data’. Those were some of the challenges we had to work on in the last couple of years so that we can make a very precise analysis of that data to point these operators in the right direction. Also, the key issue that the industry is facing is the available workforce in these industries. It is getting difficult to find experienced operators and to train them quickly and to gain that experience and to go over that learning curve. How do we make this system also operate like a knowledge repository and a knowledge capturing system that will continue to therefore get more intelligent and point the right actions to the right people? These were the kinds of questions that came from customers, and we are trying to address those one by one. With this new platform you can turn the data into actionable decisions that are then going to be making specific impact to the profitability of that operation. When you look at the organisation, it is basically the people, the processes, and therefore the technologies that gets used. The tools, the applications, the hardware, will get into the technology part of it and so making certain layers abstract, a layer that is agnostic and therefore relooking at the business processes and aligning people to the core. Again we will keep coming back to these people processes and technologies throughout the family as we release more products through the intuition family.

August 2012 | industrial automation asia 45

instrumentation & Measurement

To monitor a commercial power supply or conduct a fault analysis on elevators, a device such as a memory recorder may be used. In this article, we will address the advantages of using this type of device over a more traditional oscilloscope. By Takashi Hama, design engineer, Masanori Mita, department manager, Hioki E E Corporation

Memory Recorders For Testing T

o monitor the commercial power supply or conduct a fault analysis on elevators, a device such as a memory recorder may be used. In this article, we will address the advantages of using this type of device over a more traditional oscilloscope. In the past, in order to observe the waveforms of electrical signals, we typically turned to devices such as analogue oscilloscopes, magnetic oscillographs and pen oscillographs, including pen recorders. The ability to identify changes in electrical signals over time contributed greatly to industrial advancement. In the 1980s, test and measurement equipment manufacturers had greater access to high-speed A/D converter ICs and high-speed semiconductor memory chips, allowing them to develop waveform monitoring devices that can convert waveforms to digital data and then record them for later analysis. This technological revolution helped us replace analogue oscilloscopes with digital oscilloscopes, and magnetic and pen oscillographs with recorders that include built-in memory capacity. This represented the birth of the memory recorder. Waveform monitoring devices can be classified into two basic groups â&#x20AC;&#x201C; high-speed oscilloscopes and midto low-speed memory recorders. Oscilloscopes are advantageous for observing high-speed phenomena, but because the ground between channels is common, when measuring mechatronics-controlled circuits or similar devices where there is a mix of strong and weak signals or there are differences in the electrical potential of the ground of the measurement circuit, 46â&#x20AC;&#x192; industrial automation asia | August 2012

there is always the possibility of short-circuit accidents between the circuits or ground faults. Memory Recorders Memory recorders, on the other hand, are designed to isolate each channel individually, providing a safe and secure method for observing waveforms. This important point of differentiation has led researchers and technicians around the world to welcome the memory recorder as a formidable and indispensible test and measurement device. Furthermore, in addition to electrical signals, memor y recorders also meet the needs to simultaneously measure physical phenomena such as voltage, current, temperature, vibration, weight, acceleration and rotation. To facilitate this, some memory recorders are designed to accommodate plug-and-play input modules, providing optimum flexibility and revolutionising the way the world captures signals. Memory recorders have greatly advanced and evolved since the 1980s, and current offerings consist of compact 2-channel handheld devices, 4-channel portable formats that support high voltage input, plugand-play 16-channel models designed with superior shock resistance for application in a variety of field tests, 32-channel formats for integration into factory systems and production lines, and high-end machines packed with features and functions that represent the epitome of all that a memory recorder has to offer.

1 Basic Analogue Modules

Direct input up to 400VDC enables the measurement of 200VAC power voltages 2 High Voltage And High Resolution Modules

With a maximum direct input of 1,000 VDC and a maximum rated voltage to earth of 1,000 V AC/DC (CATII), applications involving high voltage to ground situations such as fuel cell stacks or assembled batteries are aptly met with the high voltage modules because of their capability to measure the minute voltage of each individual cell at high resolutions.

+65 6377 4001

3 Temperature And Voltage Modules

(Scanner Modules) Supporting a variety of thermocouple sensor inputs, both voltage and temperature from two to 16 channels can be scanned. 4 Strain Modules

A specialised module for receiving input from distortion gauge conversion devices enable the researcher to measure physical attributes such as weight, pressure, acceleration, displacement and torque. 5 Charge Modules

With a built-in anti-aliasing filter, this type of module supports the input of piezoelectric acceleration pickup sensors, both charge output and pre-amp types. 6 FFT Analogue Modules

Basic analog modules with built-in anti-aliasing filters, these types of modules are primarily used for FFT analysis of recorded signals.

ENQUIRY NO. 453

Input Modules It is the assortment of input modules featuring a rich array of trigger functions and measurement capabilities for accurately capturing anomalous phenomena that set the memory recorder apart from traditional oscilloscopes. By mixing and matching the plug-and-play input modules available in the larger recorder formats, customers can maximise their investment due to the ability to measure a wide variety of signals with just one device.

August 2012 | industrial automation asiaâ&#x20AC;&#x192; 47

instrumentation & Measurement

7 Frequency Modules

Frequency modules are ideal for measuring the frequency fluctuation of power voltages, as well as perform integration and measure duty ratio. 8 Current Modules

Used in combination with dedicated clamp on sensors, current modules enable convenient current measurements. 9 RMS Modules

Use specifically to record RMS fluctuations. 10 CAN Modules

With the data captured from a CAN bus, vehicle attributes such as engine rotation number, water temperature, vehicle speed, and tire pressure can be recorded as waveforms and displayed on the memory recorderâ&#x20AC;&#x2122;s screen. Triggers Triggers are an extremely important function for capturing abnormal phenomena. In high-end memory recorders, up to eight different triggers may be available, while the basic triggers are available in all memory recorders, from simple Level Triggers that activate recording as soon as the preset detection level has been exceeded, to voltage drop triggers that are convenient for monitoring commercial power voltages. By setting the appropriate AND/OR conditions between the trigger and source, the researcher can start measuring and recording when all trigger conditions are satisfied, or when only one is satisfied, presenting a multitude of usages. The typical triggers are: 1 Level Trigger 2 In Window And Out Window Triggers 3 Period In And Out Triggers 4 Glitch Trigger 5 Voltage Drop Trigger 6 Waveform Judgment Trigger 7 Event Trigger 8 Logic Trigger

Main Functions Of A Memory Recorder Almost all measurement applications using memory recorders can be fulfilled with the two basic functions of memory recorder (high-speed) or recorder (real-time) available in most devices. However, in fact there are many other functions that researchers and technicians can take advantage of in order to effectively capture anomalies. 48â&#x20AC;&#x192; industrial automation asia | August 2012

1 Memory Recorder (High-Speed Recording)

This function is most suitable for relatively capturing high-speed waveforms such as instantaneous waveforms and transient phenomena. The input signal is converted to digital data and then written into the memory recorderâ&#x20AC;&#x2122;s buffer memory. Waveforms can then be displayed on the screen or printed on paper. Because data is first saved in the internal buffer memory, high-speed phenomena that could not be caught with a traditional recorder that outputs on paper can be easily recorded. 2 Recorder (Real-Time Recording)

Ideal for long-term recordings such as for monitoring control voltages or the RMS fluctuation of power lines, this function can be compared to conventional logging or pen recording. 3 Recorder And Memory

In addition to using the Recorder function to continuously record for long durations, high-speed recording features are added so that signals near the point of trigger can be recorded at high speeds. Because the detailed portions of abnormal phenomena can be recorded during continuous measurement, by diligently segmenting the buffer memory, more than one phenomenon can be recorded in full detail. 4 FFT

Use this function to easily conduct frequency analysis on captured data. 5 Real-Time Save

Some memory recorders can also save measurement data directly to an internal hard disk, CF card or SD card. Primary Applications With the many features and functions described above, indeed a plethora of measurement applications can be met with a memory recorder. 1 Monitoring Commercial Power Supplies

Memory recorders are ideal for identifying the circumstances surrounding the power supply problems of instantaneous power outages and voltage drops due to load fluctuations. They can also be used for capturing voltage fluctuations stemming from the load of uninterrupted power supplies, and measure control signals via logic probes at the same time. 2 Utilities Generation And Power

As a monitoring instrument for the control devices of power generation (including hydropower, coal-fired or nuclear power) facilities, memory recorders are

often used in the interruption tests of generator control systems to measure properties such as the rotation rate, fuel control, and frequency, or load rejection devices.

Hioki: Memory HiCorder

3 Vehicles, Elevators And Trains

Memory recorders are also used for measuring the control signals of devices surrounding Engine Control Units using the output from various sensors. Examples include combustion pressure tests where the engine’s rotation number is inputted as an external sampling signal and the firing pressure is then measured, and more recently, electric vehicle tests involving motors and inverters. 4 Motors, Inverters And Switching Power Supplies

Recent advancements in modern power technologies are also aptly served with memory recorders, which are used to measure the control signals or current of inverter devices used to drive industrial motors, as well as to measure the temperature of various other devices. Memory recorders are particularly ideal for these types of applications because all inputs are individually isolated. 5 Digital Audio Visual Equipment

Memory recorders are also seen in audio and video applications, for example, to test for sound skips. 6 Robots And Magnetic Cards

Sensor output and other control signals emitting from robotic devices can also be conveniently monitored with memory recorders. As automation further advances, the need to test magnetic cards or ticket readers is also sufficiently met because the memory recorder can measure the entire process from card insertion to output, greatly contributing to correct operation.

The Memory HiCorder MR8847 is used to simultaneously measure and record electrical signals and physical phenomena such as frequency, temperature, vibration, weight, acceleration, rotation and logic signals. This product can accommodate up to 16 fully isolated analogue channels with 16 logic channels and records signals at a maximum sampling speed of 20MS/s. It also comes built in with functions like high speed FFT analysis, multi-channel XY recorder, waveform comparator and 20 calculation settings. These features allow on the spot signal analysis and judgement. Enquiry no. 5901 SG_Catalog_chains-cables_Layout 1 19.06.12 11:39 Seite 1

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7 Air Conditioners And Factory Maintenance

In Conclusion Born from the changing of an analogue to a digital age, today’s memory recorders have the power and capabilities to identify and capture the multitude of phenomena and greatly facilitate the smooth operation of our research, manufacturing and maintenance processes. ENQUIRY NO. 5501

Get a copy of your express catalogue today! igus® Singapore Pte Ltd 15 Shaw Road #03-02 Singapore 367953 asia-sales@igus.com.sg igus.com.sg

ENQUIRY NO. 461

Memory recorders are also seen as an indispensable tool in the development of inverters for air conditioners both for consumer and industrial use. The variety of input modules allows both the testing of compressor rotation number and measurement of current waveforms.

August 2012 | industrial automation asia 49

energy

Jeremiah Castro, Spokane, WA, US

The Power Of Water

s one of the main sources of natural energy, others being the sun and wind, water has its own unique properties and history in the lives of those seeking its use. Farmers since the ancient have used water wheels to grind wheat into flour. Placed in a river, a water wheel picks up flowing water in buckets located around the wheel. The kinetic energy of the flowing river turns the wheel and is converted into mechanical energy that runs the mill. In the late 19th century, hydropower became a source for generating electricity. The first hydroelectric power plant was built at Niagara Falls in 1879. In 1881, street lamps in the city of Niagara Falls were powered by hydropower. In 1882 the worldâ&#x20AC;&#x2122;s first hydroelectric power plant began operating in the US in Appleton, Wisconsin. How A Hydro Plant Works Hydro plants typically consist of three parts, these being a electric plant, a dam, and a reservoir; 50â&#x20AC;&#x192; industrial automation asia | August 2012

generating electricity, controlling the flow of water, and storing the water, respectively. In the dam water flows through an intake and applies pressure to the blades in a turbine causing them to rotate. Since the blades are connected to a generator, electricity is generated as a result. The amount of electricity generated by this system is dependent on the amount of water flowing through the system. the resultant electricity generated is then distributed to consumers. Compared to other methods of generating electricity, hydropower is considered one of the cheapest methods, since once the initial dam has been built the resulting energy source is free and available 24/7. There are some disadvantages to hydropower, typically related to the construction of the dam, as there can be a distributive effect on local ecology, such as changing the migration patterns of fish ultimately affecting their populations in the local area.

Alternative Hydroelectric Power Renewable energy is on the rise and greater urgency is causing a snowball effect with regards to research and related areas. Traditionally, hydroelectricity has relied on dams to act as water reservoirs as such allowing large amounts of energy to be generated. The problem is that building dams has its own side effects, and this offsets a lot of the benefits achieved through the implementation of hydropower plants. Some of the disadvantages are the dams effect on nature preservation around these vast structures. But there are alternatives and new innovation surrounding the generation of hydropower. Five alternatives are now listed: • Hydroelectricity Without Dams: The most noticeable feature of this turbine is that it can generate electricity in shallow waters. It works

•

as a paddle wheel system which remains entirely underwater. CARE Electric: This system consists of structures that contains turbine blades and needs to be suspended in the middle of the flowing river. The advantage of this sort of arrangement is that not only the horizontal flow of the water but also the vertical pressure plays a significant role in spinning the turbine blades. Hydro Green Energy: The negative side effects of the dams to the environment and marine life are completely eliminated in the Hydro Green Energy’s dual duct axial flow interchangeable hydro kinetic turbine as no large infrastructures are required. Hydrokinetic River Turbine: The hydrokinetic river turbine is a 25 kilowatt turbine and has been made by the New Energy Corp. This turbine rotates as slow enough speed to makes sure that the aquatic life is not paced at any risk. Free Flow Underwater Turbines: This system simply works like a wind turbine, the difference being that unlike wind turbines where wind is responsible for the movement of blades, here blades are moved by water currents. ENQUIRY NO. 5601

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Renewable Energy Market Growth is expected in the renewable power generation market over the next five years, according to a 2012 report by the International Energy Agency (IEA) the global power generation sector, including hydropower, solar, wind and other renewable sources, the sector is expected to increase by more than 40 percent to almost 6,400 Terawatt hours (TWh). This particular study marks the first time the IEA has devoted a medium-term report to renewable power sources. A possible indication as to the sectors increasing prominence in the overall power field. The study focused on 15 key markets for renewable energy that currently represent 80 percent of renewable generation. This report, Medium-Term Renewable Energy Market Report 2012, says that renewable electricity generation is expected to expand by 1,840 TWh between 2011 and 2017, almost 60 percent about the 1,160 TWh growth registered between 2005 and 2011. The report also states that renewable generation will increasingly shift from the Organisation for Economic Co-operation and Development (OECD) to new markets, with non-OECD countries accounting for two-thirds of this growth. The report also stated that of the 710 GW of new global renewable electricity capacity that is expected, China accounts for almost 40 percent, with significant deployments also expected in the US, India, Germany, and Brazil, among others. “Renewable energy is expanding rapidly as technologies mature, with deployment transitioning from support-driven markets to new and potentially more competitive segments in many countries,” commented IEA executive director Maria van der Hoeven.

August 2012 | industrial automation asia 51

Rising Energy Cost Eroding Profit?

Energy Efficiency

as a Business Opportunity.

National Energy Efficiency Conference 2012 19 - 20 September | Mandarin Orchard Singapore

Hear from our distinguished industrial energy efficiency experts, including James Scott Brew (Rocky Mountain Institute), Ynse De Boer (Accenture), Mads D. Lauritzen (McKinsey) and many more. Topics covered include Reinventing Fire, Sustainable Energy, Driving Energy Efficiency in Industry, Implementation of Energy Management Systems, etc. Join us at our exhibition featuring a diverse range of energy efficient technologies, practices and solutions. Who should attend: Senior management, executives, energy, facility or operational managers and policymakers who are keen to reduce energy usage in the industrial sector.

On or before 20 Aug 2012 (Early Bird)

21 Aug to 19 Sep 2012

Standard Rate

$550

$690

EENP Rate

$330

$420

For more information on this event, visit www.neec2012.sg Interested to be part of our NEEC 2012 exhibition? Contact us: exhibition@neec2012.sg

Organised by:

ENQUIRY NO. 474

Conference Fee

sector spotlight

Vision Systems:

Power Of The Sun Responding to the global need for cleaner energy, vision technology is helping solar technology suppliers to ensure quality products and increase efficiency in the value chain. By Didier Lacroix, senior VP, International Sales & Services, Cognex

he world continues in its quest for alternative sources to meet growing demand for energy. World primary energy consumption is projected to grow by 1.6 percent per annum from 2010 to 2030, according to BP Energy Outlook 2030. By 2030, this would have increased global consumption by 39 percent. Non-Organisation for Economic Co-operation and

Development (OECD) countries are expected to drive the growth of energy consumption, as the fuel mix moves away from oil and coal. Renewables (including biofuels) are the fastest growing fuels, and are expected to grow at 8.2 percent per annum. Solar power is a form of renewable energy. Photovoltaic (PV) is a means of producing

energy by converting sunlight into electricity, via the use of semiconductors. Solar energy production involves the use of panels that are made up of solar cells containing PV material. Quality Processes Solar cell production is a relatively expensive activity. Given the level of automation that is required and August 2012 | industrial automation asiaâ&#x20AC;&#x192; 53

sector spotlight

Maintaining quality is greatly improved by automation and vision technology.

the large volumes involved, quality is a decisive factor in obtaining a competitive advantage on the playing field. Manufacturers must monitor quality from incoming materials and wafers through every step of the PV value chain to achieve high-quality, high-yield solar cell production. Machine vision can help to achieve these goals, and is an enabler of precision alignment for automated wafer handling; identification solutions for part tracking, genealogy, and process control; and inspection for quality management. Machine vision can be used to detect chipped edges, saw marks, and contour defects. It can also be applied to inspect wafers for stains, contamination; and mesh pattern and dimensions, to avoid processing warped or flipped wafers. Anti-Reflective (AR) coating thickness and colour uniformity can also be checked to ensure conformity to requirements. In cell fabrication, solar cells are monitored to ensure their correct orientation before the dopant application phase. Cells are checked for chips and cracks, making sure that defective cells are rejected and removed. In the back print registration inspection stage, the vision system measures the position, width, and distance between 54 industrial automation asia | August 2012

the bus bars and ensures the continuity of finger lines. Vision is also used to align cells and inspect the edge groove cuts along the wafer edges, so as to isolate the emitters from the back of the cell. Solar cells are inspected and sorted by slight variances in colour, and the cells are graded based on colour inconsistencies. Machine vision also ensures that cells are accurately aligned for screen printing. During the solar panel manufacturing process, placement information is transmitted from the cameras to robot guidance applications for automated pick and place tasks to be performed c o r re c t l y. F o r f ro n t p r i n t registration, lines are checked for contour breaks, continuity and excess solder. Thin-Film Technology Thin-film solar cells are created by vapour-deposited or sputtered photoactive semiconductors on a glass substrate. They generally use less energy and material, and typically provide lower costs of manufacturing, compared with their silicon-based solar cell counterparts. In modern thin-film technology, each cell comprises of three layers: 1 Metal layer; 2 Semiconductor layer; 3 Transparent, electrically

conductive oxide layer.

Technology is required for pattern scribing on the solar modules by using laser and/ or needles for all the process steps (P1, P2 and P3). A typical machine comes equipped with six industrial cameras along with VisionPro software — to ensure process-tool calibration, determine wear status and check that solar modules are processed correctly. Set-up, processing and

quality inspections require just 60 seconds per module. In the first step, the machine scribes patterns in the bottom layer — also called P1 — via the use of several lasers. On Copper Indium Gallium Selenide (CIS/ CIGS) modules, mechanical tools process the two layers above this, P2 and P3. An integrated needle-comb unit accurately scribes the structures into the surface at speeds of up to 1.5 metres per second. The system can adjust quickly to different cell sizes and react accurately to changes, as every needle is individually actuated and positioned in this process. With automatic needle alignment, set-up times are minimised, allowing greater throughput to be achieved. The vision system records the actual position of the tools in a matter of seconds. Concurrently, three additional cameras measure the P1 track of the solar panel. The cameras supply three reference points for auto-alignment. Based on the location and position of the P1 structures, the software supplies information that adjusts the machine’s coordinate system and corrects the tool path. The process is aimed at minimising the displacement of the P1 structures relative to the P2 and P3 layers, in order to achieve cell efficiency. Processing tools then scribe the P2 and P3 layers to a positional accuracy of 5 µm. In the final inspection phase, two more cameras study the solar module again to identify quality issues like micro cracks, broken glass and potential detachment of layer particles. Tracking Progress A facility manufactures modules that comprise multi-layer copper/ indium/selenium solar cells in series, with a coating that has a thickness of four microns. These

cells produce high output — even in poor light conditions. During the manufacture of these cells, it is necessary to collect all the quality data from the substrate plates in each production machine. However, the individual quality results typically arrived only at the end of the production process, when the performance of the 120 x 60 cm modules were tested in the solar simulator. It was only at this point that it became certain whether a module could produce the required output of approximately 80 watts — perhaps due to fluctuations in quality. This means that the engineers were only able to ascertain the results at the end of the complex coating processes. And since quality data had not been collected beforehand, it was

often too late to determine the origins of defects. To deal with this production issue, a quality assurance solution was implemented. Each glass plate is now assigned to individual inspection stations by means of DataMatrix code identification. Data pertaining to the quality of the plate is recorded at every third or fourth step of production. The DataMatrix code is used to test whether the plate that is assigned to the data collected to date, has actually been processed. Due to glass breakage incidents, there can be situations where data sets exist but whose corresponding plate cannot be found. DataMatrix coding helps to prevent this confusion from occurring. The code is engraved onto the glass by using a laser system.

A problem that arose however, was the low contrast between the engraving and its surrounding surface. The challenge therefore, was to find a suitable vision system that could read the codes. After making comparisons, the In-Sight 5400/5100 vision sensors were found to be able to detect and decode even difficult codes on problematic surfaces, while achieving read distances of more than two metres. The laser engraving is followed by 19 processing steps. This starts from the ‘birth’ of the plate, to the application of the base coating and subsequent laser structuring to give the plates their cellular structure. A quality inspection is important at this point, as the key production step follows once the plate has been washed.

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Get more details about us Get more details about us Get more details about us Get more details about us Get more details about us Get more details about us Gavazzi Automation Singapore Ltd. - 61 Tai Seng Avenue #05-06, UE Print Media Hub, Singapore 534167 Tel: +65 67 466 990 Fax: +65 67 461 980 Carlo Carlo Gavazzi Automation Singapore Pte. Pte. Ltd. - 61 Tai Seng Avenue #05-06, UE Print Media Hub, Singapore 534167 Tel: +65 67 466 990 Fax: +65 67 461 980 Carlo GavazziAutomation AutomationSingapore SingaporePte. Pte.Ltd. - 61 Tai Seng Avenue #05-06, UE Print Media Hub, Singapore 534167 Tel: +65 67 466 990 Fax: +65 67 461 980 Ltd. - 61 Tai Seng Avenue #05-06, UE Print Media Hub, Singapore 534167 Tel: +65 67 466 990 Fax: +65 67 461 980 Carlo Gavazzi

Carlo Gavazzi Automation Singapore Pte. Ltd. - 61 Tai Seng Avenue #05-06, UE Print Media Hub, Singapore 534167 Tel: +65 67 466 990 Fax: +65 67 461 980 Carlo Gavazzi Automation Singapore Pte. Ltd. - 61 Tai Seng Avenue #05-06, UE Print Media Hub, Singapore 534167 Tel: +65 67 466 990 Fax: +65 67 461 980

ENQUIRY NO. 463

• Management of DC and environmental variables • from VMU units; AC variables, alarms and error Management of DC and environmental variables • Management of DC and environmental variables Management of DC and environmental variables • • Management of DC and environmental variables • from VMU units; AC variables, alarms and error Management of DC and environmental variables from VMU units; AC variables, alarms and error messages from inverter and energy meters from VMU units; AC variables, alarms and error from VMU units; AC variables, alarms and error messages from inverter and energy meters from VMU units; AC variables, alarms and error messages from inverter and energy meters • String, BOS and Performance ratio or Yield messages from inverter and energy meters • messages from inverter and energy meters String, BOS and Performance Performance ratio ratio or or Yield Yield messages from inverter and energy meters • String, BOS and indices calculation String, BOS and Performance Performance ratio Yield • • String, BOS and ratio or or Yield indices calculation • • String, BOS and Performance ratio or Yield indices calculation Variables shown as graphs and and numbers in indices calculation indices calculation • Variables shown as graphs numbers in indices calculation • Variables shown as graphs and numbers in in • • Variables graphs and numbers in formatted tables Variables shown shown as as graphs and numbers formatted tables • formatted tables Variables shown as graphs and numbers in formatted tables formatted tables formatted tables

August 2012 | industrial automation asia 55

sector spotlight

Quality issues are detected during inspection of screen printed patterns.

The CIS coating is applied to plates at a temperature of 600 deg C. The DataMatrix code is checked again after a chemical treatment to apply a buffer coating. After this, zinc oxide is applied to form a light-permeable front contact for the solar cell, which completes the photodiode. In the final finishing stage that follows, the plates are given additional bores to install the guide electronics for the contacts. The coated substrate glass is finally bonded permanently to the cover glass. The CIS solar panel is suited for a variety of applications such as sun collectors, electricity generation on rooftops, integrated products and stand-alone solutions. Clarity Of Vision Quality issues that are detected during the inspection of screen printed patterns include d i s p l a c e m e n t , l i n e b re a k s , chipping, shorts, halation, line width errors and foreign particles. When complex patterns are inspected with a low pixel resolution camera, image acquisition has to be divided into several steps, with the need to switch tasks. A high-resolution camera however can make a major difference by being able to capture such complicated patterns in a single pass. This simplifies work 56 industrial automation asia | August 2012

piece transportation. Coupled with the processing speed of vision tools, the quality control system is able to complete an inspection within a shorter timeframe. In order to attain greater efficiency in the conversion of light into electrical energy, solar cells need to have circuit patterns with fine line widths — which are also susceptible to breaks. A line in the pattern on a solar cell that measures 160mm by 170mm is only 100 micron wide. This implies that the quality control system must be capable of detecting defects that are as small as 70 micron, in order to identify a line break or other problems. For systems that utilise lowresolution cameras, multiple cameras have to be applied in the system, which means that repeated adjustments are needed for each camera. With a single high-resolution camera however, initial set-up costs may be somewhat higher. But in the long run, maintenance and operation costs are likely to be lower, leading to a reduction in operational expenses. And since a single processing operation is sufficient, the inspection process is also simplified. For high-quality solar cell inspection, camera resolutions may range from 11 megapixels to 44 megapixels, compared to lower-resolution solutions where five megapixel cameras are the norm. Beyond resolution, t e c h n o l o g i c a l t re n d s p o i n t towards other areas of improvement such as using various wavelength ranges; and performing multiple inspection steps with different colour and gradation settings, so as to detect even very slight deviations. There are also systems being developed that are equipped with even finer gradation capabilities to conduct inspections in greater depth.

The market for solar cells is highly promising, with greater energy conversion efficiency and quality being major factors. In the face of dwindling fossil fuels and the urgent need to turn to sources of energy that are clean, green and efficient, solar power presents an attractive resource — both reliable and sustainable in the foreseeable future and beyond. ENQUIRY NO. 5701

Product Positioning A company that is involved in renewable energy applications, required a means to inspect solar cell panels that are typically fragile. A vision solution was needed, that is capable of managing highspeed production while performing different inspection tasks — making sure that the delicate product would not be damaged in the process. The challenge that the company had was in achieving the proper alignment for the solar cells. Since it handles a variety of cells, this made the positioning task even more complex. With an automated vision system in place, it is now possible to perform the accurate centring of the solar cell, while checking for defects (eg: inspecting for broken edges or cracks), verifying dimensions, and further positioning in relation to the edges. Via a vision camera, the system calculates a cell’s position and orientation, and transmits the data to a robot. The robot then positions the cell based on these calculations, and the cell is inspected once it comes into the field of view. If defects are detected, the system notifies the robot to reject the cell. ENQUIRY NO. 5702

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sector spotlight

hile the worldâ&#x20AC;&#x2122;s energy needs are growing, energy production must turn renewable, to avoid global warming. Reducing carbon dioxide emissions and doing so by using energy more efficiently are the two key elements in an energy policy for the 21st century. Solar panels made from silicon are increasingly transforming solar rays into energy for people all over the world. Indeed, harnessing even 0.3 percent of the solar energy falling in the Sahara and Middle Eastern deserts is enough to meet the energy needs of the continents of Europe, North Africa and Middle East. Making solar power a more competitive energy source is an important step towards creating a sustainable world.

The Technology High-purity silicon is needed in making photovoltaic and solar cells. However, the solar market has seen a limited supply of such silicon. The company, Elkem Solar, addressed this need by building a facility in Kristiansand, Norway to produce 6,000 metric tonnes of high-purity silicon for solar cell panels a year. The plant became operational in July 2009. In this factory, energy consumption is 75 percent lower than in a similar factory with traditional technology. It accomplishes this by using ABBâ&#x20AC;&#x2122;s automation and power solution, integrated on the common System 800xA platform. The plant utilises an energy saving metallurgical process for producing solar-grade silicon, Elkem

Case Study:

Solar Power In A Chip In its US$600-million facility, Norwegian company Elkem Solar has embarked on industrialising the production of solar-grade silicon for solar power cells capable of generating renewable energy for more than 30 years. ABB delivered electrical high/low voltage solutions to the total plant, including the System 800xA control solution. Contributed by Ablelom Mahari, global sales and marketing, energy customer segment (Control Technologies), ABB.

58â&#x20AC;&#x192; industrial automation asia | August 2012

Solar Silicon, a future-oriented product that helps contribute to lower global CO2 levels. This new production line consists of five independent process steps for purifying silicon. System 800xA provides precise control of two of the processes, while ensuring safe and reliable operations and optimising production and energy efficiency. ABB Control And Safety Solutions For Energy Efficiency By integrating power and process systems on a common 800xA platform, ABB optimises the design and performance of Elkem’s electrical and automation systems overall energy efficiency. Plus, there are Optical Wafer Inspection the additional benefits of reduced maintenance, engineering and overall lifecycle costs. The System 800xA solution consists of several operator workplaces, five AC 800M controllers and one AC 800M High Integrity (HI) integrity controller for approximately 3,000 I/Os. The solution is comprised of Foundation Fieldbus which is used to communicate with the various types of process equipment throughout the plant. • • • • • • • •

Elkem Solar Silicon Production Process Step 1 Smelter (metallurgical silicon) — Quartz is reduced to silicon using carbon. Step 2 Slag treatment and crushing — This is the

first of three sequential purification steps to reduce impurity levels and remove boron. This involves a pyrometallurgical slag treatment where liquid silicon is transferred from the arc furnace and then solidified and crushed after treatment. Step 3 Leaching — The hydrometallurgical cleaning

process is where crushed silicon is cleaned with acids to reduce the level of phosphorus and other metallic impurities. Steps 4 & 5 Direct solidification and post-treatment

— For Step 4, the main purpose is to further reduce the levels of phosphorus and other metallic impurities. The process is similar to solar ingot production. Post-treatment involves cutting the solidified ingot into 10 kg bricks and cleaning them with acids. Parts of the ingot with an excessive concentration of impurities are cut off. ENQUIRY NO. 5703

Scope of the project: IO Check out FFB implementation and configuration FFB SW interfacing FFB Instruments parametrisation Profibus setup + SW for data mapping Commisioning assistance 800xA support Application SW modifications

Integrated Process Automation Maximises Elkem’s Capacity And Energy Efficiency The realisation of high-efficiency solar cells with low process cost is currently the most important technical issue for the major solar cell manufacturers, including Elkem. To this end, the company has developed the five-step process for purifying the silicon produced, with ABB control solutions including System 800xA controlling steps one and three of the process line.

ENQUIRY NO. 462

Platforms: • 800xA version 5.0 SP1 • Profibus • Foundation Fieldbus

August 2012 | industrial automation asia 59

EVENT PREVIEW

SPETA On Medical

Manufacturing Asia 2012

IAA spoke with Dr Ricky Souw, chairman, Singapore Precision Engineering and Tooling Association (SPETA), on an event that SPETA co-organised, Medical Manufacturing Asia. The event will take place from September 12-14, 2012, at Suntec Singapore. IAA: What do you hope to achieve with Medical Manufacturing Asia (MMA)? Ricky Souw (RS): With the growing prospects of medical technology in Singapore and Asia, MMA aims to bring together international suppliers, global medical technology players and medical technology buyers to Singapore. By so doing, we hope to propel Singapore as a medtech manufacturing hub which today is already a global leader in medical technology manufacturing especially in the areas of contact lens, micro-arrays and thermal cyclers. Importantly SPETA as a trade association representing manufacturers engaged in precision engineering and companies providing services related to the precision engineering and tooling industry, we would like to showcase in MMA the capabilities of our PE sector supporting the medtech industry. IAA: When was it decided that MMA would happen, and why now? RS: In 2010, we organised Medtech Manufacturing 2010. The aim of this event was to showcase our local suppliers. Recognising the industry potential in the region and the need for a dedicated platform to deliver the best possible quality commercial stage and business link to the dynamic region of Southeast Asia for the medical device and medical technology sectors, this partnership with Messe Düsseldorf Asia, one of Southeast Asia’s most prominent exhibition organisers in the medical and health care field, is timely and a relevant value add event for our members and the industry as a whole. The exhibition is also supported by Messe Düsseldorf, organiser of ‘Compamed’, an international trade fair for suppliers of the medical manufacturing industry. 60 industrial automation asia | August 2012

IAA: What will the defining features of MMA 2012 be, and why do you consider those features important for the current market? RS: Defining features at MMA 2012 include a wide range of technology and service solutions for use in the medical engineering industry — from new materials, components, intermediate products, packaging and services, to nanotechnology. Five key areas of focus at the exhibition include: • Components for medical technology • Materials / substance • Micro- / nano-technology • Production / manufacturing • Testing New and improved products will also be featured strongly during the exhibition including a line-up from Abrasive Engineering, Amaco Ing Vonach, ATS Automation Asia, Chiptronics Singapore, Hiwin Technologies Corporation, Ichi Seiki, Meiban Group, Mikron Singapore, Mitsui High-Tech, Servo Dynamics, to name a few. Running concurrently with MMA is the MMA Conference on September 12-13, 2012 with the theme ‘Medical Technology Products – Development, Manufacturing and Processing of Materials and Components’. The conference is jointly organised with IVAM Microtechnology Network – an international association of 300 companies and institutes in microtechnology, nanotechnology and advanced technology materials. The inaugural MMA Conference is expected to bring together major leaders and players from the medical technology industry from Singapore and overseas. The conference will offer participants insights on both global and local trends and developments of the manufacturing medical devices. There will also be Global-Asia Trade Exchange (GATE) 12 – Medical Technology, jointly organised by IE Singapore and SPETA. Through this global buyer-centric platform, international buyers from the medical technology industry can source for a wide range of products and services from end-toend precision engineering and electronics solutions such as product design and development, prototype testing, production and assembly, to supply chain and

IAA: What trends do you see in the medical manufacturing industry that you are expecting to see at this year’s show? RS: At this year’s debut edition, visitors can expect to see a strong line-up of exhibitors with comprehensive production and manufacturing capabilities including power injection moulding technology in the precision engineering of metal and ceramic components. We will also showcase plastic parts and components manufacturing contractor’s ability to offer end-to-end needs of OEM where customers can expect their program engineers on site to discuss and deliberate RFQ matters. With exhibitors specialising in automated and productivity based solutions, we anticipate more biomedical players including the pharmaceutical companies will be keen to explore what is in store for their upcoming localisation programmes. For components for medical technology, trade visitors will be able to see a broad display of filtration, separation and purification products, advanced designs and automated solutions for dental manufacturing, linear motion products such as precision ball screws and industrial robots as well as inspection and non-contact measurement systems. IAA: In your opinion, what are the key elements leading to the rapid growth of the medical device market in the Asia Pacific region? RS: The global medical device industry is growing rapidly, with value expected to hit US$228 billion by 2015, up from US$164 billion in 2011, marking CAGR of nearly seven percent, according to a recent industry research report. For the Asia Pacific market, with an average CAGR of 9.6 percent and market value expected to exceed US$71 billion by 2015, the Asia Pacific medical device sector offers significant commercial opportunities. The rapid growth of the medical device market in the region has been largely driven by strong demand for medical equipment and services, changing demographics of an ageing population and constantly increasing life expectancy, rising healthcare costs and the need for access to medical diagnosis and treatment in remote and emerging regions and in homes. Going forward, other factors impacting positively on the medical equipment and supplies market in the Asia Pacific will include technological innovation, rising cases of chronic diseases such as cardiovascular

At A Glance Exhibition title : Medical Manufacturing Asia 2012 The Manufacturing Processes for Medical Technology Exhibition Date : September 12-14, 2012 (Wednesday to Friday) Venue : Suntec Singapore, Hall 401 Opening hours : 10.00am to 6.00pm Frequency : Biennial, with the 2012 edition being the inaugural run Expected exhibitors : 150 exhibitors from 20 countries Expected visitors : 5,000 trade visitors and decision makers Jointly organised by : Messe Düsseldorf Asia Singapore Precision Engineering & Tooling Association In collaboration with : IE Singapore and SPRING Singapore Supported by : IVAM Microtechnology Network Messe Düsseldorf GmbH, organiser of ‘Compamed’ Concurrent exhibitions : Medical Fair Asia 2012 OS+H Asia (Occupational Safety + Health Exhibition for Asia) 2012

disease and diabetes, and a combination of increases in medical tourism and advertising of products directly to potential patients and consumers. The global medical device industry is likely to continue going from strength to strength, with the US remaining a key leader due to technological innovation and demand from growing markets such as India and China. ENQUIRY NO. 5801

piGRIP™

- taking gripping to new dimensions

A modular suction cup that fits most machines and that can be optimized for gripping almost all materials is now here. Piab’s latest innovation piGRIP™ is modular with independent configurable lips, bellows and fittings, which allows you to optimize the suction cup so that it fits your material and machine perfectly. Visit www.piab.com for more information.

Piab Asia Pte Ltd • 4008 Ang Mo Kio Ave 10, #03-16 Techplace I, Singapore 569625 • Phone: +65 6455 0076 Piab AB • Box 4501, Täby SE-18304, Sweden • Phone: +46 8 6302500

ENQUIRY NO. 366

distribution services. This business matching event is designed to be highly focused and targeted such that buyers will be matched with the most suitable suppliers based on their requirements through a prequalification process.

August 2012 | industrial automation asia 61

EVENT PREVIEW

National Energy Efficiency Conference 2012

Energy Efficiency National Partnership The EENP is a voluntary partnership programme launched by NEA in 2010 that helps companies that wish to be more energy efficient. The EENP programme comprises three components: Energy Management Systems Adoption of Energy Management Systems among partner companies EENP Learning Network and National Energy Efficiency Conference Opportunities for the learning and sharing of energy efficiency ideas, strategies, technologies, best practices, standards and case studies EENP Recognition Scheme Recognition of the ef for ts and achievements of corporations and corporate teams in excellent energy management practices and energy efficiency improvements.

The National Energy Efficiency Conference (NEEC) 2012 will take place from September 19-20, 2012, at Mandarin Orchard Singapore, with the theme ‘Energy Efficiency as a Business Opportunity’. Attend this conference to learn more about energy efficiency policies and programmes, energy management systems, benchmarks, good practices, innovations and new technologies. The NEEC is part of the Energy Efficiency National Partnership (EENP) Learning Network programme. This conference provides thought leadership in energy efficiency and brings together energy efficiency experts and industry energy professionals to share best practices and success case studies. Speakers include industrial experts such as Paul Westbrook 62 industrial automation asia | August 2012

(Texas Instruments), Franz Gruter (Green Datacenter), Tim Shire (KBC) and Lim Say Leong (ABB). Conference topics include: • I m p l e m e n t i n g a n O n l i n e Energy Management System to ISO50001 compliance • Developing Singapore’s energy efficiency capabilities • Driving energy efficiency in industry: public and private sector perspectives • Integrative design for energy efficiency There will also be an exhibition featuring a diverse range of energy efficient industrial technologies, practices and solutions. September 19-20, 2012 Mandarin Orchard Singapore ENQUIRY NO. 5802

ENQUIRY NO. 5803

EENP Awards The EENP Awards aim to foster a culture of sustainable energy efficiency in Singapore, especially among the major energy-consuming industries. The inaugural EENP Awards ceremony was held at the Suntec Singapore International Convention and Exhibition Centre on May 24, 2011. There are three award categories: Excellence in Energy Management, Best Practices, and Outstanding Energy Managers of the Year. ENQUIRY NO. 5804

ENQUIRY NO. 428

EVENT REVIEW

Water Week Report

Automation To Power Future Cities Singapore’s largest urban sustainability conference and exhibition, comprising three international events, World Cities Summit, Singapore International Water Week and CleanEnviro Summit, was held at Marina Bay Sands, Singapore, from July 1 to 5, 2012. Sitting on reclaimed land, the Marina Bay Sands Convention Center was the ideal location for plenary sessions, conferences and business forums. Over 18,500 top leaders, experts and delegates, including 100 mayors, governors, and government officials from 104 countries/regions on water and environmental technologies and sustainable city strategies, were in attendance. Prime Minister Lee Hsien Loong, who officially opened the week, pointed out several key trends. The world’s urban population will grow at an unprecedented rate to nine billion people by 2050, such that 70 percent of the world population will live in cities by then. “This creates enormous pressure to ensure that infrastructure, housing and services and the environment meet current and future generation needs,” said Khoo Teng Chye, executive director of the Centre for Liveable Cities. The co-location of the three events, therefore, attempts to address fundamental challenges on water, 64 industrial automation asia | August 2012

The triple event week of World Cities Summit, Singapore International Water Week and CleanEnviro Summit reveal the potential of automation in urban sustainability. By Augustine Quek

environmental, waste and other components together as a whole for sustainable growth. The key question that the week attempts to answer was: How can the increasing number of urban inhabitants enjoy a high quality of life with access to basic services, shelter and employment and at the same time build sustainability, biodiversity, inclusiveness and resilience to the impacts of climate change into the cities? At the opening Plenary, the question was partially answered by Helen Clark, administrator of United Nations Development Programme and former PM of New Zealand and professor Tommy Koh, Singapore’s Ambassador-at-large. Technology, together with good governance, were crucial factors in developing livable and sustainable cities. Although it was not directly stated, optimising the use of resources efficiently and effectively, especially in water, energy and waste management, would require automation systems and processes. The Key Is Automation It was clear, even before the week officially started, that automation is key in meeting the challenges

Technology Utilisation The common and recurring theme of technology utilisation also permeated throughout the series of

workshops, seminars and talks. At WasteMET Asia’s Beacon Conference, several scenarios based on automation technologies were envisioned. To cope with the unprecedented quantities of waste that is expected in the coming decades, physical and organisational systems for waste management would have to include predicting waste spatially and temporally. Real-time sensing and response components required as the amount of information to collect has increased exponentially. Sensors would need to be in place to track waste movement and collect data on waste transport. Part of this tracking system would use satellite technology, to monitor waste movement and plant facilities. This information can be made available in the public domain, such as on the Internet. Another vision was the widespread use of Automated Solid Waste Collection System (AVAC), especially in an underground setting. In addition, highly autonomous and unmanned underground freight systems to convey waste and materials that are safer, more efficient and less costly. Multi-purpose underground tunnels with extended lifetime could also be developed with centralised operational control. These visions all depend heavily on the development of automation technologies.

+65 6243 6781 phoenixcontact.com.sg

ENQUIRY NO. 472

of the future. At the ‘Smart Water Grid Workshop’ co-located event, the experiences of several water providers using smart water networks told the same story. Sensors, meters, remote monitoring and control, control centres and data analytics, the conventional automation components, will form the backbone of future smart water networks. Remote terminal units, automated remote controlled valves and Supervisory Control And Data Acquisition (SCADA) were discussed for demand and pressure monitoring in a smart water network. From private operators like the Manila Water Company to government boards like the Metropolitan Waterworks Authority in Thailand, automation systems for better data collection and analysis, demand response and prediction were key issues. Sophisticated remote monitoring of water quality is already a reality. The Fish Activity Monitoring System (FAMS), showcased at TechExchange by ZWEEC Analytics, is an automated system that uses cameras to monitor the activity of fish. Video images are analysed for signs of distress to detect possible water contamination. If large numbers of fish die, an alert will trigger to automatically collect a water sample for detailed testing. Also unveiled was Urban Prototyping, which uses integrative tools for computer aided planning and design on the urban level. These tools, similar to the simulation and prototyping tools used in product engineering and manufacturing, help planners visualise and identify the best urban design solutions. Instead of a particular product or part, complex systems modelling techniques are used to simulate the built environment of a city and its impact on resource utilisation, environment, people and costs are analysed. One such particular tool is being tested on the pilot Greenprint neighbourhood in Jurong East in the west of Singapore, providing information such as temporal solar variation and spatial waste production. It comes as no surprise that current technologies used in industries to minimise raw material wastage, reduce energy consumption and optimise machinery capacity are also going to treat and deliver water; control demand and supply of electricity (‘smart grids’), plan networks and regulate traffic flow, regulate buildings environmental impact, and manage waste disposal systems for entire cities. This is because the main driver of growth in cities cannot be maintained if planning and resources are not optimal and ecosystems are not protected.

August 2012 | industrial automation asia 65

EVENT REVIEW

Sustainable cities were a main attraction at this year’s show

The Exhibitors This year’s triple expo also saw automation leaders such as ABB, Rockwell, Emerson, Siemens and Schneider Electric exhibiting alongside Asian competitors like Yokogawa, Mitsubishi, NEC, Toshiba and Panasonic. At the Water Expo, Mitsubishi Electric, for example, unveiled its MC Works 64, an advanced SCADA software package that is integrated into it MELViz iQ PlantSuite, an integrated supervisory automation control and monitoring system solution. It includes MC AppBuilder, a multi-function feature that comprises graphical database, PLC control programs and communication interfaces. At the World Cities Summit Expo, Panasonic showcased its Total Energy Solutions that can be scaled from homes to entire towns. The solution comprises of Panasonic’s HIT photovoltaic panels, its lithium-ion battery Smart Energy Storage System, ECONAVI electrical appliances featuring intelligent sensors, and Home Energy Management System (HEMS). The company also opened its first Energy Solutions Development Centre in Singapore. The R&D centre will look into developing and integrating technologies for creating, storing, saving and managing energy. Automation also plays a role in urban health. NEC introduced its Food, Animal and Plant Safety System (NEC FAPS), a web-based monitoring system for food safety, animal health and plants and their products. Other than capturing critical information on import, inspection and laboratory findings, the system’s advanced analysis capability can issue alerts when anomalies are detected. The NEC FAPS mobile computing feature allows inspectors to access critical data online and enter data during inspection on-site via a 3G enabled mobile tablet device. Local players also featured strongly at the three expos, with well-known names like NCS, Sembcorp, Keppel Integrated Engineering and ST Engineering. At 66 industrial automation asia | August 2012

WasteMET Asia Expo, STSE Engineering, a subsidiary of ST Marine, showcased its CleanVac, an automated pneumatic waste collection system. The system works by depositing pre-sorted pieces of solid waste at specific drop-off points, triggering sensors and are conveyed through a network of pipes to fixed collection stations. As it is fully automated, it can operate round the clock, and mobile versions of the system have been built. At the World Cities Summit Expo, NCS revealed its answer to the smart city, Solutions for an Urbanised Future (SURF). SURF integrates emerging technologies and solution themes for smart cities, including the Internet-of-Things (IOT), Analytics and Big Data, Machine-To-Machine (M2M), Security, Social Networking and Mobility. This means that repositories of historical data as well as real-time data and statistics in transport, healthcare utilities and education can be analysed for trends, predictions and optimisation. These databases can be interlinked to give insights to city planners and designers into the changing dynamics of people, the city conditions and its environment. One application could be to use traffic information, from M2M communications between vehicles and road infrastructure to enable monitoring and prediction by transport authorities to manage traffic, sending out alerts to drivers about accidents, diversions and road works. Urban dwellers would also be able to use their smartphones or tablets to access information from household appliances such as ovens, refrigerators and air-conditioners, controlling them remotely or over the Internet. In Conclusion The automation technologies available today are already capable of solving the most pressing urban problems. Water desalination, wastewater treatment, waste-to-energy plants and landfill-togas plants already use a range of sensors, meters, communications protocols, control stations, and conveyors. The week closed on a high, with a new record of S$13.6 billion (US$10.7 billion) in announced total value in projects awarded, tenders, investments and R&D MOUs made at the event. From the experience of the three co-located events, automation technologies can only become more prominent as infrastructural and resource demands from cities continue to grow. July 1-5, 2012 Marina Bay Sands Singapore ENQUIRY NO. 5805

Renewable Energy Asia 2012

June 2012 witnessed significant new support for the environment with the introduction of important new environmental events in Bangkok, Thailand. The new exhibitions were: ‘Renewable Energy Asia 2012’ and ‘Boilex 2012’, both of which were co-located with Entech Pollutec 2012 and Pumps & Valves Asia 2012 and both of which fill pressing needs in the environmental arena. All four co located events took place between June 6 to 9, 2012, at BITEC in Bangkok, Thailand. ‘Renewable Energy Asia 2012’ featured a display of energy systems and technical know-how from international companies in a wide variety of renewable areas. It also proved of great interest to businesses keen to lower their energy costs and protect the environment. The other new exhibition ‘Boilex Asia 2012,’ is being introduced at the perfect time as the Thai market for industrial boilers is now growing rapidly in keeping with the Kingdom’s economic boom.

The need for modern, efficient boilers is also set to grow even further with the introduction of the ASEAN economic community in 2015. ‘Entech Pollutec’ and ‘Pumps & Valves Asia’, both of which have been running for many years, accompanied the two new events and proved a perfect match by providing excellent symmetry with systems and equipment necessary for environmental excellence. Altogether over 200 companies displayed their technology at this event, which included solar power companies: Suntech, Yingli, Trina Solar, Canadian Solar, Sunpower, Jinko, Co-energy, Sungen, China Synergy and Bosch. National Pavilions Featured Many companies displayed their products and systems at special National Pavilions that included Japan, China, Germany, Taiwan, and Singapore. A benefit of the Pavilions was the interchange of ideas that was seen resulting in

positive networking opportunities as businesses and entrepreneurs covering a wide variety of industries discovered new opportunities. Over 200 seminars were presented including special presentations such as Germany’s Renewable Energy Day; a seminar from the Thai Chamber of Commerce; ‘Community’s Energy Station for Sustainable Energy & Agriculture and a ‘Low Emission Society’ Seminar delivered by JETRO of Japan. All presentations were well attended and proved of networking value to the dozens of companies in attendance. Following the success of the exhibition many exhibitors are looking forward to returning to BITEC for the 2013 shows which are expected to be even more rewarding as the need for renewable energy and related technology continues to grow. June 6-9, 2012 BITEC Bangkok, Thailand ENQUIRY NO. 5806

August 2012 | industrial automation asia 67

products & Services Aerotech: Rotary Stages

Banner Engineering: High Intensity

A CCS series of rotary stages from Aerotech features integral pneumatic collet chucks for automated material handling. The series supports precision laser machining and micromachining of tubular products in plastics, metals and many other materials. It is particularly suited for cylindrical tube laser machining of medical products including stents and fine tubes. Using readily available collets, the CCS stages support tube diametres from 0.1 mm to 27 mm. A clear aperture assures efficient product feed-through. Housings are designed to accept wet-cutting accessories, and the stages tolerate inevitable moderate leakage of cutting fluid into the aperture.

Five EZ-Light high intensity indicators, from Banner Engineering, provide clear long-range visibility in intense sunlight or brightly lighted indoor conditions. All use advanced LED technology to provide longer life and lower energy consumption than fluorescent or incandescent light sources. All EZ-Light models have rugged neutral-coloured housings that definitively indicate whether lights are on or off. They are offered with a wide range of power options and mounting hardware. Custom capabilities include lights with five colour combinations selected from nine available colours.

Enquiry no. 5902

Agilent: Modular Solar

LED Indicator Lights

Enquiry no. 5904

Endress+Hauser: Liquiline

Array Simulator

Multichannel Transmitter

Power available from a solar module is highly dependent on its illumination and temperature. The maximum available power, also known as the Maximum Power Point (MPP), changes with operating conditions. For inverter design, development and qualification, it is critical to test with a variety of MPPs which means exposure to a predictable, repeatable and broad range of illumination and temperature conditions for extended periods. The Agilent E4360 solar array simulator provides controllable, consistent, stable, and wide-ranging solar module performance for your testing needs.

Liquiline CM444 and CM448 multichannel transmitters by Endress+Hauser for monitoring and controlling processes in water & wastewater, chemical, power and other industries, accept inputs from up to eight of the companyâ&#x20AC;&#x2122;s Memosens digital sensors including nitrate, Spectral Absorption Coefficient (SAC), pH, ORP, conductivity, dissolved oxygen, turbidity, free-chlorine and ion selective electrode sensors. The device recognises any combination of Memosens sensors and starts operating immediately. Memosens technology means all sensors can be precalibrated in the laboratory. When connected to the Liquiline series of transmitters â&#x20AC;&#x201D; sensors are recognised automatically. This makes the exchange of sensors fast and maximises the uptime of the measuring point.

Enquiry no. 5903 68â&#x20AC;&#x192; industrial automation asia | August 2012

Enquiry no. 5905

products & Services

Faro: Six-Axis Portable Measurement Arm

The Faro Prime, is a six-axis portable measurement arm that delivers value to customers who require a high-accuracy, contact-only measurement solution for everyday inspection and quality assurance routines. Available in four lengths from six to twelve feet (1.8m to 3.7m), the Faro Prime promises accuracies as tight as .019 mm (.0007 in). The product is also Bluetooth equipped, eliminating the need to tether the device to a laptop. An extendeduse battery and composite material construction ensure shop floor durability, day after day. Together, these features make the Prime the ideal solution for basic measurements in inspection, reverse engineering, CAD-topart analysis and anywhere else a high-accuracy, hard-probing measurement solution is needed. Enquiry no. 5906

Hioki: Clamp On

Earth Tester

Hioki E E Corporation has developed a slim and energy efficient ‘Clamp On Earth Tester’, the FT6380 and FT6381. These products were developed in response to the demand of customers’ needs in measuring multi-grounded systems. A 50 percent reduction in power consumption allows continuous measurement of up to 35 hours. The basic model FT6380 comes with standard measurement functions, and the FT6381 with Bluetooth data transfer capabilities, which also allows connectivity to GPS maps. Enquiry no. 5908

Festo: Pneumatic Valve

Hitachi: SJ700 Series Drive

The valve range VUVG from Festo has an improved size-toperformance ratio owing to the company’s patented cartridge principle offering greater dynamics and up to 100 percent more flow for faster cycle times. The valves are particularly suitable for use in automation applications where cost-effective, small-scale, technologically universal solutions with high flow rates are required, as is the case in the electronics, solar, textile and packaging industries, and in special machine construction. The compact dimensions and low weight of the aluminium housing also make the valves ideal for use in the front-end area, eg: mounted directly on a robot arm.

The SJ700 Series drive offers features such as sensorless vector control, starting torque >200 percent, high-torque multimotor operation (with SLV), motor auto-tuning (online/ offline), integral easy sequence programmable functionality (EzSQ), safe stop according to EN9541, RS485 and RS422 interfaces, PID control, P/PI control, automatic voltage regulation, motor thermistor input, user macro saving and global standards to CE, UL, c-UL, C-Tick. It is suited to applications such as packaging, printing, textile, machine tool industries, lifts, cranes, centrifuges, extruders and any application which requires high starting torques.

Enquiry no. 5907

Enquiry no. 5909 August 2012 | industrial automation asia 69

products & Services

Nord Drivesystems: Inverter

The intelligent SK 540E i n v e r t e r, f r o m N o r d Drivesystems, supports the convenient and free programming of driverelated functions according to IEC 61131. It has all the established features of the series but supports a wider range of drives than any of its sister models; in particular, it can control synchronous motors. It integrates a universal encoder interface for energy recovery. SK 540E performs tasks without an external PLC, as such saving costs. Pump drives, for instance, can be upgraded with monitoring functions and characteristic curve functions, enabling them to directly react to fluctuating flow rates. Enquiry no. 5910

Yokogawa: Network-Based

Control System

Yokogawa Electric Corporation has released an enhanced version of the Stardom network-based control system. This enhanced version includes modules that enable the FCN autonomous controller to communicate directly with facilities and devices that use the Profibus-DP and CANopen industrial communication protocols. An IT security setting tool is also provided to assist in the configuration of the same security models employed by Yokogawaâ&#x20AC;&#x2122;s Centum VP integrated production control system. Enquiry no. 5912

Phoenix Contact: HMI

Zebra Technologies: Printers

The TP 5000 devices, which feature an Intel Atom 1.6GHz CPU, are enclosed in an IP65-rated aluminium housing, which is dust protected and water resistant at the front, meaning they can be utilised in virtually any sector. Visu runtime software is available on three different displays for visualisation; the display runs diagonally from 30.73cm (12.1in) to 43.2cm (17in). Multi-station operation can be set up by connecting an external monitor. Some of the benefits include IP allocation via the engineering station or PLC for commissioning, connection monitoring for operating tasks and location identification functionality for service and support.

Zebra Technologies Corporation has released the ZT200 printer series, a line of printers intended for light industrial and commercial applications. The series offers advanced printer integration capabilities and complete device management. The ZT200 tabletop printers allow organisations to improve efficiency in a variety of verticals. Some of the specific uses include: manufacturing, light work-in-process tracking, inventory management; transportation and logistics, order picking and packing, shipping and receiving, and compliance labelling; retail, warehouse logistics and back-of-store applications; healthcare, specimen labelling and pharmacy labelling.

Enquiry no. 5911 70â&#x20AC;&#x192; industrial automation asia | August 2012

Enquiry no. 5913

Calendar Of Events 2012/13 august

9 – 11 Industrial Expo Penang 2012

Penang International Sports Arena (PISA) Penang, Malaysia Intrenasionale Email: info@intrenasionale.com Web: www.intrenasionale.com

29 – 1 Sep Taipei International Industrial Automation Exhibition 2012

Taipei World Trade Center Nangang Exhibition Hall Taiwan Chan Chao International CO., LTD. Email: show@chanchao.com.tw Web: www.autotaiwan.com.tw/en/index.asp

September 5 – 7 Semicon Taiwan 2012

Taipei World Trade Center Nangang Exhibition Hall Taiwan Taiwan External Trade Development Council,TAITRA Email: ehuang@semi.org Web: www.semicontaiwan.org/en/

12 - 14 Medical Manufacturing Asia 2012

Suntec Singapore Singapore Messe Düsseldorf Asia Pte Ltd Email: teresa@mda.com.sg Web: http://www.medmanufacturing-asia.com

19 - 20 National Energy Efficiency Conference 2012 Mandarin Orchard Singapore Singapore Roxwell Pte Ltd Email: anthony@roxwell.com.sg Web: www.neec2012.sg

26 – 28 Thailand Lab 2012

BITEC Bangkok, Thailand N.C.C. Exhibition Organizer Co., Ltd Email: thailandlab@vnuexhibitionsap.com Web: www.thailandlab.com

21 - 24 All Industrial Expo 2012

october

3 – 5 Power Gen Asia 2012

Impact Exhibition and Convention Centre Bangkok, Thailand PennWell Conferences & Exhibitions Email: exhibitpga@pennwell.com Web: www.powergenasia.com

4 - 6 Metalex Vietnam 2012

Saigon Exhibiton and Convention Center Ho Chi Minh City, Vietnam Reed Tradex Email: rtdx@reedtradex.co.th Web: www.metalexvietnam.com/

10 – 13 IGEM 2012

Kuala Lumpur Convention Centre Malaysia Expomal International Sdn Bhd Email: igem@expomal.com Web: www.igem.com.my/2012/index.html

22 – 25 Singapore International Energy Week Marina Bay Sands Singapore Energy Market Authority Email: ema_siew@ema.gov.sg Web: www.siew.sg/

Jakarta International Expo Jakarta, Indonesia Krista Exhibitions Email: info@kristamedia.com Web: www.allindustrialexpo.com

27 – 30 OSEA 2012

Marina Bay Sands Singapore Singapore Exhibition Services Pte Ltd Email: es@sesallworld.com Web: www.osea-asia.com/

december 4 – 7 ConBuild Mining Vietnam 2012

Vietnam Exhibition Fair Centre (VEFAC) Vietnam MMI Asia Pte Ltd Email: info@conbuild-vietnam.com Web: www.conbuild-vietnam.com

5 – 7 Semicon Japan 2012

Makuhari Messe Japan Semi North America Email: jstandards@semi.org Web: www.semiconjapan.org/en

5 – 8 Manufacturing Indonesia 2012

november 6 – 10 China International Industry Fair 2012 Shanghai New International Expo Centre China Shanghai World Expo (Group) Co., Ltd. Email: ciif@shanghaiexpogroup.com Web: www.ciif-expo.com/

6 – 10 Industrial Automation Show 2012

Shanghai New International Expo Centre China Hannover Milano Fairs Shanghai Ltd. Email: ias@hmf-china.com Web: www.industrial-automation-show.com

Jakarta International Expo Kemayoran Indonesia PT. Pamerindo Buana Abadi Email: info@pamerindo.com Web: www.pamerindo.com

January 30 - 1 Feb Semicon Korea 2013

Coex Center Seoul, South Korea Email: semiconkorea@semi.org Web: http://www.semiconkorea.org

To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Editor IAA Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building, #02-05, Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 • Email: iaa@epl.com.sg

Advertising Index

IndustrialAutomationAsia

ADVERTISING I N D E X

ADVERTISER

PAGE NO ENQ NO 454

ADVERTISING SALES OFFICES

ABB PTE LTD

IFC

Adder Technology (Asia Pacific) PTE LTD

444

HEAD OFFICE

Agilent Technologies Singapore (Sales) PTE LTD

464

Carlo Gavazzi Automation Singapore PTE Ltd

463

SINGAPORE Eastern TRADE MEDIA PTE LTD 1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: 65-6379 2888 Fax: 65-6379 2805/6379 2806

D’Mark Technologies (S) PTE LTD

457

Denso International Asia PTE LTD

452

Emerson Process Management Asia Pacific PTE Ltd

IBC

386

EPSON Singapore PTE Ltd

466

Faulhaber Singapore Pte Ltd

456

FESTO PTE LTD

471

FLIR SYSTEMS CO., LTD

442

Fuji Electric Asia Pacific PTE Ltd

469

Hioki Singapore PTE Ltd

455

Honeywell PTE Ltd

459

SINGAPORE: salesIAA@epl.com.sg

MEDIA REPRESENTATIVES JAPAN:

IFM Electronic PTE Ltd

473

Igus Singapore PTE Ltd

43/49

460/461

JJ-Lapp Cable (S) PTE Ltd

462

Messe Dusseldorf Asia PTE Ltd

448

Mitsubishi Electric Asia PTE Ltd

OBC

468 450

National Instruments (S) PTE Ltd

Panduit

465

Phoenix Contact (SEA) PTE Ltd

472

PIAB Asia PTE Ltd

366

Rockwell Automation South East Asia PTE Ltd

458

ROXWELL PTE LTD

474

Schneider Electric Singapore PTE Ltd

467

Sick PTE Ltd

451

Siemens PTE Ltd

470

Singapore Exhibition Services PTE Ltd

428

SPECTRIS PTE LTD – Red Lion Controls

453

Ted Asoshina Echo Japan Corporation Tel: 81-3-32635065 Fax: 81-3-32342064 aso@echo-japan.co.jp

KOREA:

Young-Seoh Chinn Jes Media International Tel: 82-2-481 3411/3 Fax: 82-2-481 3414 jesmedia@unitel.co.kr

TAIWAN:

Robert Yu Worldwide Services Co Ltd Tel: 886-4-23251784 Fax: 886-4-23252967 sales@wwstaiwan.com The closing date for placing advertisements is not less than FOUR WEEKS before the date of publication. Please contact our nearest advertising office for more details.

This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.

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Semi-Conductor Foundry Services Semi-Conductor Equipment Mfg Electrical & Electronics Mfg Automated Assembly Precision Engineering & Sub-contracting Aerospace Automotive Material,Storage & Handling Systems Design & Programme Building and Construction Rubber & Plastic Manufacturing Assembly/Packaging

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Food & Beverage Processing Pulp & Paper Oil & Gas Production Power Generation Chemical and Pharmaceutical Manufacturing Environmental Management Water & Waste Water Management & Recycling Shipbuilding & Repair Trade Association/Institutions/Government Agency Agents/Distributors/Representatives Others (Please be specific)

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50 52 54 56 58 60

Executive Management Maintenance Engineering Manufacturing Engineering Design Engineering Packaging Engineering Process Engineering

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62 64 66 68 70 72

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System Support Engineering Testing & Inspection/Quality Control Purchasing/Sourcing Research & Development Sales & Marketing Others (Please be specific)

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❑ 002 11 – 30

❑ 003 31 – 50

❑ 004 51 – 100

❑ 005 101 – 499

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There’s no way I can get all the I/O change orders done before start-up. But we can’t start-up until the change orders are done.

YOU CAN DO THAT

ENQUIRY NO. 386

Get the flexibility you need–where and when you need it–with Electronic Marshalling. Tight project schedules and changing requirements are the norm, not the exception, so Emerson makes handling them easy by eliminating re-wiring altogether. Only with DeltaV Electronic Marshalling can you land field cabling wherever and whenever you want, regardless of signal type or control strategies. It’s the flexibility to add I/O today, tomorrow or ten years from now. See how DeltaV Electronic Marshalling makes it easy, scan the code below or visit: IOonDemandCalculator.com

ENQUIRY NO. 468