IAA October-November 2010

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October/November 2010

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October/November 2010

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Pneumatic Valves & Drives | PLM | Vibration Analysis Training

Vibration Analysis Training:

E-Learning vs The Classroom PLM:

A Strategy Of Sustainability Optimising Ethernet Performance In

| Optimising Ethernet Performance

Manufacturing Plants Pneumatic Valves:

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Rockwell Rockwell Automation Automation Southeast Southeast AsiaAsia Pte Pte Ltd Ltd Singapore Singapore Tel Tel : +65 : +65 6510 6510 6688 6688 Indonesia Indonesia Tel Tel : +6221 : +6221 255255 45200 45200 Malaysia Malaysia Tel Tel : +603 : +603 8997 8997 6688 6688 Philippines Philippines Tel Tel : +632 : +632 323323 0588 0588 Thailand Thailand Tel Tel : +662 : +662 936936 1500 1500 Vietnam VietnamTel Tel : +848 : +848 6255 6255 6400 6400 www.rockwellautomation.com/sea www.rockwellautomation.com/sea

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contents October/November 2010

ISSUES & INSIGHTS

22

Industrial Ethernet: Battling It Out

With growing applications and demand, various technology providers are vying for a larger slice of the pie. By Michael Volz, MD, HMS Industrial Networks

CONTROL POINT

26

Going Easy With Motorised Actuators

Equipped with the latest technological features, actuators offer convenience for the machine manufacturer, the production floor and maintenance personnel. By Charles Lim, customer support centre manager, Oriental Motor

30

Pneumatic Valves & Drives: Strength In Application

Having undergone constant improvements, valve terminals offer a host of functionality in a compact size.

By Christopher Haug, Festo

SOFTWARE & NETWORKS

35

PLM: A Strategy Of Sustainability

In a sea of increasing costs and constant change, manufacturing companies have to adopt the right practices in Product Lifecycle Management (PLM) to stay afloat. By Rama Tiwari, director, Autodesk South East Asia

Instrumentation & Measurement

38

Vibration Analysis Training: E-Learning vs The Classroom

Imparting skills for vibration analysis and certification. Is one approach better than the other? By Bill Slonaker, Mobius Institute

SECTOR SPOTLIGHT

Energy

42

46

Process Gas Analysers: Sifting Out

Understanding the pros and cons of the various technologies that are available to the natural gas industry – and making a choice.

By Michael W Markus, Sick Maihak 4  industrial automation asia | Oct/Nov 2010

Creating Energy From Waste

Technologies are available that can effectively convert discarded waste into a sustainable source of energy.

By Augustine Quek

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contents

z IndustrialAutomationAsia

October/November 2010

www.iaasiaonline.com

October/November 2010

Vibration Analysis Training:

Pneumatic Valves & Drives

October/November 2010

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

E-Learning vs The Classroom PLM:

|

A Strategy Of Sustainability

| Vibration Analysis Training

The Business Of Going Green

Ben Earwicker, USA

Strength

www.iaasiaonline.com

Mutually compatible machine tool lubricants and proactive maintenance can help deliver the competitive edge in manufacturing. By Peter Bird, European marketing advisor, ExxonMobil Lubricants and Specialties

Gentle Cover: Festo

10/6/10 11:07 PM

Industrial Automation Asia (IAA) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: www.iaasiaonline.com Email: iaa@epl.com.sg

Industrial Ethernet: Machine Vision

The Perfect Match

Pneumatic Valves:

IAA Oct2010.indd 2

Advances in technology are paving the way for more powerful machine vision applications. By Neil Chen, product manager for Vision Products, Adlink Technology

55

Optimising Ethernet Performance

In the face of environmental, social and governance challenges, CEOs in Asia are increasingly embracing sustainable practices in the playing field. By Teo Lay Lim, country MD; Ynse de Boer, senior manager, Sustainability Services, Accenture Singapore

53

Optimising Ethernet Performance In

Manufacturing Plants

|

48

PLM

fEATURES

58

Optimising Ethernet Performance in Manufacturing Plants

The consideration of environmental risks and the selection of suitable hardware are essential to longterm network performance and reliability. By Bill Wotruba, director, Networking and Connectivity Products, Belden

EVENTS Singapore International .

Energy Week

64

OSEA 2010 PS Asia 2010, HVAC & Refrigeration Asia

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Interphex Asia 2010

Regulars

Refer to pg

10 Industry News

69 Products & Services

16 Profibus

71 Calendar of Events

18 CAN in Automation

72A Product Enquiry Card

20 Fieldbus Foundation

6 industrial automation asia | Oct/Nov 2010

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EDITOR’s PAGE

The

Strength Of Small

Published by:

EASTERN TRADE MEDIA PTE LTD (A fully owned subsidiary of Eastern Holdings Ltd) Managing Director

Kenneth Tan editor

Michael Tham michaeltham@epl.com.sg Editorial Assistant

Nicole Yee nicoleyee@epl.com.sg Senior Art Director/Studio Manager

The tiny island state of Singapore continues to make strides in its economic development. As a testament of its investment appeal, Mitsubishi Heavy Industries is establishing MHI Industrial Engineering & Services in Singapore in October.

The establishment serves to handle the company’s machinery and steel structures business. With a view towards long-term expansion, it functions as a marketing and service base for environmental and chemical plant projects in South East Asia and the Middle East.

To keep the ball rolling for foreign investment, national industrial infrastructure developer JTC is stepping up its efforts in solutions.

Among the projects that are in its pipeline are feasibility studies like the ‘Cluster Industrial Concept with Mega-hoist’ and the ‘Plug-and-Play Factory’ – an initiative that could result in land savings of up to 30 percent. The corporation will also be launching a number of projects like the Offshore Marine Centre, General Aviation Centre, MedTech Centre and the Surface Finishing Complex.

In the area of power generation, the GMR Group is commencing the construction of a combined-cycle power plant. It will be one of the first in Singapore to use LNG from the LNG terminal on Jurong Island.

As part of its drive to promote manufacturing excellence, Yokogawa Electric Asia’s facility in Singapore has been presented with the 2010 Manufacturing Excellence Award (MAXA). The facility has raised its production by five times from S$200 million (US$149 million) to S$1 billion over the past 30 years.

The country is also setting its sights for growth beyond its local shores. Moving farther east, the Singapore-Sichuan High-Tech Innovation Park creates a platform for Singapore-based companies to get involved in the development of the central and western regions via partnerships with Chinese enterprises. The project will begin with an initial start-up area of 10 square kilometres.

While it may not have the physical size of Goliath on the world map, having the heart of David may be what is necessary for Singapore to carry on riding the wave towards greater economic success.

Michael Tham Editor

Lawrence Lee lawrencelee@epl.com.sg Graphic DesignerS

Jef Pimentel jeffreypimentel@epl.com.sg Zhang Yue zhangyue@epl.com.sg contributing Graphic Designers

Libby Goh Ahmad Halik Assistant Sales Managers

Cindy Chan cindychan@epl.com.sg Delcia Ng delciang@epl.com.sg CIRCULATION EXECUTIVE

Azizah Nawi azizahnawi@epl.com.sg Contributors

Michael Volz, Christopher Haug Charles Lim, Rama Tiwari, Bill Slonaker Michael W Markus, Augustine Quek Teo Lay Lim, Ynse de Boer, Neil Chen Editorial Consultants

Jim Pinto Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

supported by:

EASTERN HOLDINGS LTD executive Board Chairman

Stephen Tay GROUP EXECUTIVE DIRECTOR

Kenneth Tan Financial Controller

Robbin Lim

etm

Eastern

Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: Eastern Trade Media Pte Ltd 1100 Lower Delta Road #04-02 EPL Building Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: www.iaasiaonline.com Email: iaa@epl.com.sg MICA (P) No. 039/07/2010 ISSN 0219/5615 PPS 1561/06/2011 (028597) Co Reg No. 199908196C Printer: Fabulous Printers Pte Ltd

8 industrial automation asia | Oct/Nov 2010

System 800xA Extended Automation The Power of Integration

Profitable collaboration. Operational excellence can only be achieved through collaboration between people and systems. ABB’s System 800xA Extended Automation platform provides the collaborative environment necessary for various organizations and departments to work as one. Utilizing System 800xA’s patented Aspect Object Technology, information is integrated from various plant systems, applications, and devices and presented as one plant-wide view enabling informed, real-time decision making. That’s the power of integration.

For more information visit www.abb.com/controlsystems

ENQUIRY NO. 173

Industry News Yokogawa Awarded For Manufacturing Excellence In Singapore Singapore: Yokogawa Electric Asia has received the 2010 Manufacturing Excellence Award (MAXA) for its achievements in operational excellence, innovation and sustainability as a core global manufacturing site in Singapore.

The facility is the most productive in the company’s global network and accounts for 75 percent of the group’s global supply of distributed control systems and measuring instruments. Leveraging Singapore as a vantage point to integrate production management methodology from Japan with automation knowledge from Europe and the US, the facility has increased its output five-fold from S$200 million (US$149 million) to S$1 billion over the past three decades.

With the Singapore team recognised for its expertise in manufacturing excellence, the facility is also designated as the company’s global training centre to share and impart best manufacturing practices for its employees in all overseas plants and offices. In addition, Yokogawa’s Singapore plant is the first site outside of Japan to develop and carry out scale-up manufacturing for the company’s foray into avionic products.

JTC Develops Innovative Industrial Solutions Singapore: JTC continues to support Singapore’s economic needs by developing innovative infrastructure solutions for businesses despite a challenging global economic environment in 2009. As Singapore enters the next economic phase, JTC will step up its efforts in delivering ongoing key projects and industrial concepts to anchor new investments in Singapore.

The corporation will be launching several industry-level infrastructure projects that will derive synergies from clustering complementary industry activities together. These include the Offshore Marine Centre, General Aviation Centre, MedTech Centre and the Surface Finishing Complex.

The other concepts on which feasibility studies are being conducted are the ‘Cluster Industrial Concept with Mega-hoist’ and the ‘Plug-and-Play Factory’ which could result in land savings of up to 30 percent.

JTC is also exploring ways of reducing construction time for industrial facilities in Singapore. The corporation is looking into construction methods and technologies that can improve site accessibility, and the use of precast and prefabrication works which aims to cut construction time by 10 - 15 percent.

The corporation’s other major developments that are making inroads into new frontiers are in the areas of competitiveness and environmental sustainability. The projects include `Jurong Island Version 2.0´ which aims to introduce schemes to reduce carbon emissions, and recycle wastewater and chemicals, and CleanTech Park and CleanTech One. 10 industrial automation asia | Oct/Nov 2010

Hanlong Bases International HQ In Singapore Singapore: Hanlong Group, one of the top 20 largest private companies in Sichuan Province in China, has announced that it will invest US$100 million in the research and development of solar energy solutions, system assembly and international headquarter activities in Singapore. This is through its wholly-owned subsidiary Sichuan Zhonghan Solar Power.

The Group has chosen Singapore as its International Headquarters to manage its global solar business outside China. This includes the assembly and sale of its Concentrated Photovoltaics (CPV) systems as well as the management of its solar farm projects targeted for regions such as Australia, Middle East and South East Asia. The company will also set up a R&D centre in CPV which will collaborate with the Solar Research Institute of Singapore (SERIS).

Said Mr Liu Han, Hanlong Group's Chairman: "We chose to set up our first regional headquarters in Singapore because of its reputation as a global hub for clean energy, in particular solar energy.”

Industry News

Island Power To Begin Construction Of Power Facility

Singapore: The GMR Group, which acquired a 100 percent ownership stake in Island Power in 2009, will release the execution of a 800MW combined cycle power facility on Jurong Island in the third quarter of this year.

The Siemens-Samsung consortium will provide a turnkey Engineering Procurement Construction Combined-Cycle

Power Plant (EPC CCPP) comprising two SGT5-4000F gas turbines in single shaft configuration.

The power generating facility will be one of the first in Singapore to use Liquefied Natural Gas (LNG) from the LNG terminal on Jurong Island and is slated to be completed and operationally ready in 2013.

Singapore & Sichuan To Lead Hi-Tech Innovation Park Development Singapore: The development of the Singapore-Sichuan High-Tech Innovation Park (HTIP), a project supported by the Singapore-Sichuan Trade and Investment Committee (SSTIC), will be spearheaded by the private sector from Singapore and Sichuan.

On the Singapore side, a consortium is being formed to jointly lead the project with its counterpart from Sichuan.

First raised at the 12th SSTIC meeting held in Singapore in June this year, the Singapore-Sichuan HTIP project saw more details firmed up following a meeting between Singapore SSTIC Advisor1 with Sichuan Party Secretary Liu Qibao and Sichuan SSTIC Advisor Governor Jiang Jufeng in Chengdu, Sichuan province.

During the meeting, both parties agreed on adopting a private sector-led approach for the project. A Memorandum of Understanding (MOU) for the collaboration is expected to be signed between both secretariats of the SSTIC. At the same time, the Singapore consortium is expected to sign a separate MOU with Chengdu Hi-Tech Zone to set the parameters of collaboration and commit to a joint feasibility study for the project.

Said Lim Swee Say, minister, Prime Minister’s Office: “Sichuan serves as a leading gateway to the central and western regions of China. The proposed innovation park presents a platform for our Singapore-based companies to

participate in the development of the central and western regions through a close partnership with Sichuan and China enterprises. By combining the strengths of both sides, we can jointly showcase the development of modern manufacturing, services and living using the innovation park as a pilot site. This project will be commercially driven by the private sector and supported by the SSTIC. We believe it will generate many downstream opportunities for Sichuan and Singapore-based companies, including but not limited to areas such as master planning, infrastructure services, ICT and new media, healthcare and education, lifestyle and entertainment, retail and tourism, and technology and innovation.”

The project will involve the building of a 35 square kilometre development in the South Park of the Chengdu Hi-Tech Zone.

The project will commence with an initial start-up area of 10 square kilometres.

It will integrate modern manufacturing, modern services and modern living into one, with emphasis on high technology and low carbon industries, as well as R&D. It aims to become a key regional business hub and gateway for businesses expanding into West China.

1 The SSTIC Advisors are minister Lim Swee Say and Sichuan governor Jiang Jufeng, while the co-chairmen are MOS Koo Tsai Kee and Sichuan vice governor Huang Xiaoxiang.

Oct/Nov 2010 | industrial automation asia 11

Industry News

Asia Pacific Generator Sets Market Picks Up Steam KL, Malaysia: Fuelled by the upturn in economic activities, opportunities are unfolding for participants in the Asia Pacific generator sets market, according to Frost & Sullivan. The commercial and industrial end users are expected to be the major customer segments procuring generator sets for stand-by and prime power applications.

Among the various distributed power generation technologies, generator sets are preferred and are poised to continue their dominance in the foreseeable future.

Being one of the proven technologies for backup power, they are also cost effective and have a simple operating mechanism and easy procurement channels.

The market earned revenues of US$765.3 million in 2009 and is estimated to reach to US$1.12 billion in 2016.

Self-Sufficiency “As Asian countries are dominated by energy-intensive industries, the need for reliable and stable power supply is a top priority for this segment,” says program manager, Suchitra Sriram. “To deal with unexpected power outages, all major industries and commercial buildings prefer to own generator sets.”

Revival of stalled projects in the construction and infrastructure segments

is expected to stimulate the demand for generator sets. Moreover, expansion plans in the manufacturing, mining, and process industries are likely to ensure that demand remains robust in the near term.

The growing need for uninterrupted power supply has made generator sets indispensable as a stand-by application.

Apart from this, the region’s topography makes it difficult to provide extensive grid coverage for remote rural areas and far-flung islands. In such places, generators sets are used for prime power application.

Although the outlook for the market looks bright, trends point to a low annual growth rate and varying demand patterns in each country.

Some challenges have clouded the market landscape; the well-developed infrastructure and availability of cheap electricity from utilities have impaired market progression. The investment cap on equipment by industries, commercial enterprises, and institutional end users has also proven to be a hurdle.

Aside from this, the generator sets market was severely affected by the global economic downturn and several projects were either pushed to the back burner or cancelled due to lack of credit.

Increasing imports from China have made

it challenging for multinational companies to sustain their market share.

“With issues pertaining to climate change and global warming gaining significant attention, end user awareness of Renewable Energy (RE) and energy efficient technologies has been ramped up considerably,” says Sriram. “RE technologies such as wind, solar Photovoltaic (PV), and biomass power are gaining popularity among the distributed onsite power generation technologies because of their long-term benefits that include no fuel costs, no emissions, no operational costs, and simple operating mechanisms.”

Also, with new high-rise buildings under construction gravitating toward green energy, the growth of the generator sets market has been curtailed.

To remain successful in this highly price-sensitive space, generator set dealers must fine-tune their aftersales strategies by providing ready accessibility to spare parts and ramping up customer support. Moreover, they must ensure timely attendance to customer complaints.

Providing project finance and undertaking strong brand building measures will enable customer retention and help secure repeat business.

MHI To Establish Subsidiary In Singapore Tokyo, Japan: Mitsubishi Heavy Industries (MHI), will establish MHI Industrial Engineering & Services (MIES) in Singapore effective October 1, which will handle the company’s machinery and steel structures business. MIES is aimed to function as a marketing and service base for environmental and chemical plant projects in the South East Asia and Middle East regions, where market expansion is expected over the long term.

The new company will also serve to execute part of Engineering, Procurement and Construction (EPC) projects, such as procurement activities. Future plans call for MIES to broaden its business scope from environmental and chemical plants to other product areas and become a regional business base for other operations in machinery and steel structures.

The company will undertake a variety of engineering projects, including gas and oil production facilities, flue-gas desulfurisation systems and carbon dioxide (CO2) recovery systems, in addition to its primary focus on chemical plant projects.

12 industrial automation asia | Oct/Nov 2010

Mitsubishi Heavy Industries Singapore Private Ltd (MHISP), a wholly owned subsidiary of MHI, will hold 100 percent of MIES’s capital, which will be S$2.4 million (US$1.79) upon establishment but is subject to future increases in step with business expansion.

The markets for environmental and chemical plants are basically in expansionary trends along with economic growth and population increases in the emerging countries.

Competition in these markets is intensifying, however, due to the significant ascendancy of South Korean companies – with Chinese companies expected to catch up in the future – and rivalry among engineering companies in Japan, Europe and the US. To respond to these market conditions, MHI has been faced with the task of maintaining and enhancing its ability to deal promptly, dynamically and locally with customers in areas ranging from project development to construction and completion of plants.

Industry News

Nestlé Lanka Expands With Chilling Centre

(L-R): Speaker of parliment Chamal Rajapaksa, Environment Minister Anura P Yapa, Nestlé Lanka chairman Antonio Helio Waszyk, Nestlé Lanka MD David Saudan and Nestlé Lanka MD designate Alois Hofbauer.

Kilinochchi, Sri Lanka: Nestlé Lanka has inaugurated a chilling centre in the northern province of Kilinochchi in Sri Lanka, furthering its expansion in the dairy industry.

The facility, which will add to the company’s 106 other chilling facilities

in the country, was officially opened

by Chamal Rajapaksa, speaker of the Parliament, and Anura P Yapa, minister of environment. The company plans to invest in eight more before the end of this year.

With a capacity of 1,600 litres and

testing equipment to ensure the quality of milk, the facility will be serviced by milk collection points established by Nestlé Lanka in Kandawalai, Kilinochchi, Visuwuamadhu, Wattakachchi, Uruththirapuram and Iranamadu.

Harting Inaugurates Centre Of Innovation

Bio-Based Twist Film Packaging Breakthrough

Rahden, Germany: The Harting Technology Group has officially opened its Centre Of Innovation in Rahden, Germany. The group’s seventh plant in east Westphalia employs about 120. “On an area of around 5,000 square metres we have created an atmosphere in which ideas can grow and innovations can be conceived,” explained Philip Harting, senior VP Connectivity & Networks.

The departments due to take up their work in Rahden include Industrial Communication and Power Networks (ICPN), an integrated program which provides Ethernet network components, cabling and wiring across all company divisions.

The Norms and Standardisation department will also be moving into the facility. The staff are involved in national and international standardisation committees in the development of norms and standards, as well as being responsible for registering and monitoring patents belonging to the group.

Staff from the marketing and product management department of the Device Connectivity division will also be working in Rahden.

California, US: Cereplast, a manufacturer of bio-based, compostable and sustainable plastics, has partnered with Sezersan Ambalaj (Sezersan), a subsidiary of Asc Group in Turkey, to produce bio twist films made from compostable resins. Said to be the first-of-its-kind, the product will serve as wrap packaging for a variety of food products distributed throughout Europe.

Under the terms of the agreement, Cereplast will begin monthly shipments of 100 to 150 metric tonnes of bio resin in December 2010. The bio twist film has substantial form memory capability (dead-fold behavior) and is heat sealable. The film may be made into opaque or semi-transparent, film-like material. The bio twist film will be used as packaging for a variety of brands in the food industry in Europe.

This year, Cereplast is on track to ship 16 million pounds of bio-plastic resins to customers around the world, an increase of 400 percent from last year, in response to surging consumer and industrial demand for economically and ecologically sound, ‘green’ products.

Oct/Nov 2010 | industrial automation asia 13

Industry News

Patrick Nijhuis, Netherlands

Belden Provides Cabling Solution to DIAL

New Delhi, India: New Delhi International Airport Private Limited (DIAL) has chosen Belden for a structured cabling

solution. In taking over the management of Indira Gandhi International Airport in New Delhi, the former

inherited a number of legacy IT systems which were not fully integrated. The company wanted a solution that would fully integrate these systems and optimise operations.

Working with IBM Global Business Services, Belden identified the key client requirements for limited downtime, location tracking, flexibility (with easy add/remove), and improved maintenance for the Local Area Network (LAN) setup.

Shell & PetroChina Complete Arrow Energy Acquisition The Netherlands: Shell and PetroChina have completed their joint acquisition of Australian coal seam gas company, Arrow Energy.

The acquisition follows an offer in March 2010 to purchase 100 percent of the shares of Arrow by CS CSG (Australia), a 50/50 joint venture company owned

by Shell Energy Holdings Australia and a subsidiary of PetroChina Company. CS CSG (Australia) agreed to pay A$4.70 (US$4.30) cash per share for all of the shares in Arrow, representing a total consideration

of approximately A$3.5 billion.

“This acquisition is underpinned by rising global demand for gas as a clean source of energy,” said Malcolm Brinded, Royal Dutch Shell’s executive director of Upstream International. “ S h e l l ’s L N G e x p e r t i s e a n d PetroChina’s access to the Chinese energy market, together with the coal seam gas resources and expertise built up

by Arrow’s staff, will further consolidate Australia’s position as a global leader in energy and resources supply.”

“As a leading natural gas producer, PetroChina welcomes this opportunity to work with Shell to expand our international LNG and natural gas production and supply activities through the acquisition of Arrow Energy,” said Qiliang Bo, VP of PetroChina Company.

Arrow will remain based in Brisbane, Australia, with a board of directors composed of Shell and PetroChina executives. The new CEO of Arrow is Andrew Faulkner.

Opening Of Lenox/Irwin Asia Pacific Distribution Centre

Shanghai, China: Lenox and Irwin have established an Asia Pacific distribution centre in Shanghai Waigaoqiao Free Trade Zone. The establishment of the centre is a step in the growth plan for the tool business in Asia.

The Asia Pacific Distribution Centre is developed from former Lenox Asia Pacific Welding and Distribution Centre. Aiming to fulfill the increasing market demand 14 industrial automation asia | Oct/Nov 2010

in Asia, particularly in China, the group made an investment to expand the former distribution centre. The centre occupies 4,000 square metres.

With the manufacturing industry prospering in the Asia Pacific region, especially in China, the market demand for high-technology and high-quality tool products and services has been growing.

The centre will provide clients with products and services through its capability of warehousing, customised cutting and welding. An Asia Pacific Sawing Technology Training Centre is also affiliated with the distribution centre. The training centre will provide clients, customers, technical support engineers and sales engineers with testing technologies and training programs.

“Now our pressure instrumentation is more versatile than ever!�

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ENQUIRY NO. 176

Industry Updates

Quality

Profisafe

With

One of the most important steps in the technological development of Profibus & Profinet International (PI) is the completion of Profisafe, the specification for functional safe communications for Profibus.

This is a development in safetyoriented automation and opens up a range of options. Since 2005, the Profisafe profile has also been available for use in Profinet IO systems. The relevant approvals from TÜV and German Institute for Occupational Safety and Health (BGIA) were awarded on conclusion of the t e c h n o l o g y ’s d e v e l o p m e n t .

Profisafe has since become an international standard - IEC 61784-3-3. Steps are also currently

being taken to establish it as a national standard in China.

Since its first publication, it has become a leading technology for functional safe communications.

By the end of 2007, more than 41,000 plants were in operation with a total of more than 410,000 P ro f i s a f e n o d e s – o f w h i c h approximately 10 percent are in process automation plants.

The quality of products and systems is crucial, particularly in areas of safety. And in order to guarantee these for Profisafe, PI has initiated a range of structural and organisational measures.

These include documents, such as the ‘Profisafe Policy’ and ‘Environmental Guideline,’ the

introduction of certification for Profisafe products, the setting up of competence centres, and training courses with a final exam for qualification as a ‘Certified Profisafe Engineer’.

Status & Application

P ro f i s a f e o f f e r s a u n i f o r m profile for safety applications on the basis of Profibus DP and Profinet IO networks. It is used in exclusively Profibus DP (V1 mode) or Profinet IO networks (V2 mode), but is also ideal for crosssystem use in mixed networks (V2 mode) with both Profibus DP and Profinet IO. Profisafe has also since been approved for wireless transmission technologies, such

Figure 1: Coexistence of standard and safety communications

16 industrial automation asia | Oct/Nov 2010

Figure 2: Architecture of Profisafe

as WLAN and Bluetooth. When incorporated with data security technology, it can be used over Ethernet backbones.

It is used for safe communications in both manufacturing and process auto­ mation, and offers the following advantages: reduced cabling, flexibility during commissioning, e x p a n s i o n a n d / o r re v a m p , consistent engineering and diagnostics.

Profisafe defines how failsafe devices communicate with safety controls over a network so that they can be used for safety-relevant automation tasks up to PL4 acc, ISO 13849-1 or SIL3 (Safety Integrity Level) acc, and IEC 61508. To achieve this safe communication, it uses a profile, ie: a special format of the user data and a special protocol. The spectrum of devices ranges from safe I/O modules

Figure 3: Profisafe in Profibus and Profinet systems

of the remote I/O, emergency stop pushbuttons, light curtains, laser scanners, overfill safety systems, transmitters for drives with integrated safety functions and robots.

The Profisafe profile uses the black channel principle, which specifies that the safety layer is independent of the underlying transmission path, ie: includes the Profinet/Profibus transmission and the backplane buses of PLC and field devices.

Profisafe can be easily

i m p l e m e n t e d o v e r s o f t w a re and when used in conjunction w i t h P ro f i b u s a n d P ro f i n e t , covers the spectrum of safety applications in process and manufacturing automation. If the software of Profibus DP devices is upgraded to V2 mode, the Profibus DP interface only n e e d s t o b e re p l a c e d b y a Profinet IO interface to enable operation directly on Profinet IO networks.

ENQUIRY NO. 7101 Oct/Nov 2010 | industrial automation asia  17

Newsdesk CANopen For CANopen is the standardised communication system for decentralised and distributed embedded control systems. It provides basic communication services such as transmitting in real-time messages containing process data (PDO communication). However, this broad- or multicast service is not confirmed. To read or write to a parameter list (object dictionary) of another device, the confirmed SDO client/server service is used.

The CANopen application layer also provides Network Management (NMT) functionality.

The device with the NMT master functions controls the NMT state machine of all networked devices.

As an add-on, the CANopen NMT slave devices may request the NMT master to start or to stop other devices. This function, as well as self-starting CANopen devices are described in the CiA 302 series of specifications (version 4.0).

The CiA 302 specification has been completely re-chaptered.

Part 1 contains some general definitions. Part 2 defines in detail the NMT boot-up procedure and the flying NMT master concept.

Flying NMT masters are required in mission- or safety-critical network applications, where a single failure should not lead to a complete network shutdown. In case that the NMT master device fails, another NMT master capable device takes over.

If the original NMT master device recovers from the failure 18  industrial automation asia | Oct/Nov May 20092010

Automation Applications Master

situation, the actual redundant NMT master device gives the NMT master functions back to the original one. This mechanism is controlled by four different protocols as described in CiA 3022. There may be more than two NMT master capable devices in the network. The system designer assigns different priorities to the NMT master capable devices.

The highest prior NMT master device will always be the actual NMT master.

Part 3 of CiA 302 specifies the program download and configuration manager. These additional functions are used in decentralised control systems, where one entity – the CANopen manager device – configures all devices after power-on. In extreme, the CANopen manager always downloads the entire application into the connected devices. This guarantees that all application programs are compliant to each other.

Otherwise there may be a scenario where one substituted device uses a software version which is not consistent with the software running in some other devices. The software download is performed by means of segmented SDO communication.

There are special object dictionary entries reserved for up to 254 application programs.

In part 4, the use of network variables is described.

Programmable devices have no pre-defined process data. For that reason, the object dictionary provides in the address range from A000h to AFFFh network variables.

A f t e r d e v i c e p ro g r a m m i n g , they have a specific meaning and may be mapped into PDOs that are accessed by means of SDO communication. Network variables are the process image of programmable devices. In CANopen networks, there may be several programmable devices installed. They may even share simple pre-programmed I/O modules, sensors, or actuators.

This is then a real distributed control system with several application masters.

Par t 5 specifies the SDO manager, an additional CANopen function for NMT master devices.

The SDO manager is necessary, if a simple CANopen device with just the SDO default server is to be configured on-line by an external tool. In this case, the tool rents the correspondent SDO client from the NMT master device. This avoids the situation where two devices access the simple CANopen device using the same CAN-IDs. Many of the more sophisticated CANopen manager devices increasingly support the SDO manager function.

B u s - l i n e re d u n d a n c y a s requested in marine and other mission-critical application fields is defined in part 6 of the CiA 302 specification set. There is a default

CANopen devices that provide stand-by NMT master functions allow the implementation of the Flying NMT master concept

Application Programming Interface LSS Master/Slave

Flying Master*

SDO Manager SRD*

NMT NMT SYNC EMCY Master Slave Handler Handler

Client SDO Handler

Local Object Dictionary Server SDO Handler

PDO Handler

CAN Driver/CAN Message Handler CANopen Master/Slave Software *Optional Add-on Modules

CANopen

bus-line and a redundant one. If the default is corrupted, all connected devices will automatically switch to the redundant one. An additional PDO error counter is used to decide when to activate the redundant busline. The first combinations of busline redundancy and safety-related communication as specified in CiA 304 (CANopen Safety protocol) were for train applications.

Part 7 describes the CANopento-CANopen router and bridge functions. The original request came from companies that have cascaded several CANopen networks, for example in mining machinery. Pertaining to SDO and Emergency communication, it is a router function. PDOs are forwarded with the bridge functionality; this means that the content of the PDOs are not changed at all. Only the CAN-ID may be changed.

The SDO router function requires an additional SDO command, which is sent before the normal or expedited SDO. This SDO router command indicates which device in which network shall be addressed by the following SDO. The system designer must of course configure

the router by means of router tables.

The same has to be done for remote emergencies, which are forwarded by the router to another network. The number of networks in hierarchical or meshed network systems is limited to 127. The configuration of router/bridges devices can be locked in order to avoid accidental configuration failures.

With the additional CANopen functions defined in the CiA 302 specification set, the CANopen users can also design complex and sophisticated network systems for mission-critical applications. Some of these functions are required in rail-vehicle applications, an application domain that is gaining importance. That is why CANopen will be internationally standardised as an in-vehicle network for locomotives, coaches, and train-sets (IEC CD 61375-33). The additional CANopen application layer functions are also suitable for industrial automation applications, eg: in distributed embedded machine control systems.

ENQUIRY NO. 7102 Oct/Nov May 2009 2010 | industrial automation asia  19

Fieldbus Foundation Releases Updated Technical Specification The Fieldbus Foundation has announced that an updated version of its Foundation fieldbus technical specification is now available. The specification includes guidance supporting the development of fieldbus devices and host systems that employ advanced field diagnostics as per the NAMUR NE107 recommendation, as well as support for the upcoming H1 Interoperability Test Kit (ITK) 6.0.

The foundation’s specifications define the open, non-proprietary foundation fieldbus protocol.

The technology provides an alldigital, two-way, multi-drop communications link among smart field devices and automation systems. It serves as the network for instruments used in process automation, and has a built-in capability to distribute the control application across the network.

According to foundation manager — Fieldbus products, Stephen Mitschke, the specification reflects growing industry demand for, and adoption of, NE107 field diagnostics. He said: “Field diagnostics, as implemented in Foundation fieldbus, standardises how today’s intelligent devices communicate – regardless of the vendor. This technology ensures that the right message will be delivered to the right person in the plant, at the right time. Operators, engineers and technicians not only receive detailed information, but it is provided in a categorised manner that makes data easier to assess and act upon.”

Mr Mitschke added: “The 20 industrial automation asia | Oct/Nov 2010

updated specification also defines the minimum requirements for the testing of hosts employing Foundation for Safety Instrumented Functions, which is a platform for advancing standards-based solutions for plant SIFs. FF-SIF enables process end users to realise significant reductions in their total cost of ownership by extending fieldbus benefits into plant safety systems.”

Foundation fieldbus specification version 2010.1 includes: • Updates to the CFF Specification (FF-103) and Function Block Specification (FF-890, FF-891 and FF-892) to reflect changes implemented in the soon-tobe-released (ITK) 6.0. This includes support for required field diagnostics capabilities, which standardise how all fieldbus devices communicate their diagnostic data to process control and asset management systems. The test kit will also employ a new intuitive user interface. Additional ITK 6.0 features will include support for testing Custom Profiled Function Block s, software components built with VC9, and compatibility with the USB interface hardware available from National Instruments.

• Updates to the Host Profile Specification (FF-569), which include new FF-SIF host test requirements, as well as ‘B’ host profile support for all

newly registered fieldbus hosts.

Host features that have gone from ‘optional’ to ‘mandatory’ with the ‘B’ host profiles include: Configuration and Access to Field Diagnostics, Block Instantiation, Multiple Capability Levels, Enhanced Function Blocks, Profiled Custom Function Blocks, Configuration of Scheduled Control Function Blocks, and DD v5.1 Device-level Access. Support for NE107 field diagnostics is required as part of the second phase of host testing and registration.

• Addition of a Block Instantiation and Capability Levels Application Note (A N - 0 0 8 providing guidelines to both host a nd dev ice vendors on how to ha ndle system interoperability considerations.

• Update of the Foundation fieldbus AG -181 System Engineering Guidelines to version 3.1, which provides the definition of the design, specification, installation, configuration, and commissioning for a Foundation fieldbus-based control system.

Fieldbus Foundation members p u rc h a s i n g o r re n e w i n g a specification maintenance agreement will be able to download a complete copy of the Foundation fieldbus H1 and HSE Specifications, including all updates to these specifications from the Fieldbus Forums.

ENQUIRY NO. 7103

ENQUIRY NO. 126

issues & insights

T

he importance of industrial communications systems is constantly increasing. It is becoming more difficult to find a larger machine or production plant delivered without containing a fieldbus system or industrial Ethernet network.

While the automotive industry is playing the role of technology driver with its increasing use of industrial Ethernet, the more conservative indust r y sector of proce ss automation is now discovering the benefits of fieldbus technology.

Market research studies predict growth for fieldbus and industrial Ethernet communication systems.

There is almost no other industrial sector where engineers can develop their creativity, finding many different solutions to the same basic problem. For standard fieldbuses like Profibus, DeviceNet, CANopen, and CC-Link, technology development has stabilised.

In the area of industrial Ethernet networks and for sensor actuator networks, the technology is rapidly evolving and diversifying. Figure 1 illustrates how today’s diversified market has emerged from two basic technologies: fieldbus and Ethernet.

The future introduction of industrial wireless communications systems and sensor actuator networks will continue the growing technological development and diversification.

All About Performance While some focus on increasing performance, others are inventing completely new industrial Ethernet solutions. Competition for the highest performance is entering the gigabit level. Beckhoff has raised the performance bar with its EtherCAT technology. Profibus International (PI) is following up with a performance-optimised Profinet and Japan-based Mitsubishi has crossed the gigabit border with its CC-Link IE Field network.

Not all 28 competing industrial Ethernet systems will gain notable

22  industrial automation asia | Oct/Nov 2010

Industrial Ethernet:

Battling ItOut

With growing applications and demand, various technology providers are vying for a larger slice of the pie. By Michael Volz, MD, HMS Industrial Networks

DeviceNet, CANopen, CC-Link, and Modbus have extended their importance. Whereas special networks like FIPIO and proprietary networks show declining figures.

This is confirmed by a market research report by IMS Research (see Figure 2), which analysed the market shares of industrial networks in manufacturing technology.

Even six years after the launch of industrial Ethernet and with increasing node numbers, the majority of production plants are networked with established fieldbus systems. Current news from fieldbus user organisations show that

standard fieldbus systems have not yet passed their prime. Contrary to all former expectations, established fieldbuses still show a moderate increase of installed nodes. The expected rapid replacement of fieldbus systems by industrial Ethernet is happening at a slower pace than anticipated.

Figure 1 Starting with only two communications systems in 1975, the number of market-relevant communications systems has increased tenfold

ENQUIRY NO. 169

market share. The question is which ones will, and why. Various criteria need to be considered: performance, price and the market power of the respective technology driver will be the deciding factors.

It is expected that the number of market-relevant real-time Ethernet solutions will settle at around 10 different solutions. In Europe and North America, it is likely that Profinet and Ethernet/IP will gain market leadership. In Japan, it is expected that Mitsubishi’s industrial Ethernet version CC-Link IE Field will become the dominating technology.

W hen it come s to dr ive technology, Sercos III and EtherCAT should also play an important role. EtherCAT has also gained a remarkable market share in machine building industry.

On the field level, established open fieldbus systems like Profibus,

Oct/Nov 2010 | industrial automation asia  23

issues & insights

Figure 2: Market shares of industrial networks in manufacturing automation.

Source: IMS Research, 2008.

All established fieldbus systems have stable specifications and there is a wide spectrum of suppliers. End user and system integrators securely handle the systems during installation, maintenance, and troubleshooting.

Today, nearly all fieldbus systems feature an integrated solution for the transmission of safety related data (eg: Profibus: ProfiSafe, DeviceNet: CIP-Safety), thereby enabling the transmission of standard data and safety related data over the same cable. This will open up further applications, which are currently often wired with separate cables.

Growing Importance Industrial communication is increasingly involved in the area of simple sensors and actuators.

The primary motivation is to be able to transmit diagnosis and status messages in addition to I/O data. This can further reduce e n g i ne e r i n g e f fo r t s du r i n g the planning, operation and maintenance of a plant.

Until now, the Actuator Sensor interface (AS-i) has been one of the most widely used open communications standards for the lowest field level. AS-i’s success has brought competitors on the scene and new systems are entering the market.

Europe has launched IO-Link, while the US has introduced CompoNet, and Japan has unveiled CC-Link/LT. All networks are specifically tailored for the requirements of very simple field devices. Special gateways provide the integration of the newer

sensor/actuator networks into the higher-level fieldbus or industrial Ethernet systems.

The use of wireless communications systems is still in its initial phase. Since basic technologies like Bluetooth and Wireless Local Area Network (WLAN) do not meet industrial requirements, it is expected that every fieldbus user organisation will work out its own ‘standard’, just like with industrial Ethernet.

The HART Communication Foundation (HCF) is pioneering the way with Wireless HART, a solution which specifically aims at the requirements of process automation. The experts from Profibus International (PI) count on the Wireless sensor and Actor Networks ( WSAN) technology as their solution for wireless communication in the sensor actuator area.

The A merica n ODVA ha s specified its own wireless solution for the CIP network family. Due to the different technical approaches, users are advised to thoroughly test compatibility with already existing radio networks.

In the face of a variety of industrial networks, it is a good idea for device manufacturers to equip their devices with highly flexible communication interfaces. In-house development will not always lead to the lowest cost solution, as costs of components are just the tip of the iceberg.

Ready-to-install communication modules are often a cost-effective option. Using these solutions could help to reduce development expenditures and risks for the device manufacturer up to 70 percent, while time-to-market can be significantly shortened. The question about the right fieldbus system boils down to just an optional item in the bill of materials – and the automation device should provide the desired interface.

ENQUIRY NO. 7201

24 industrial automation asia | Oct/Nov 2010

ENQUIRY NO. 160

control point

M

echanical actuators are important systems in the automation industry – they convert the elements of compressed air or the rotary motion of an electric motor into a useful action. For example, if an automated linear motion is required, the use of an electric motor itself will not be able to create that motion; hence a screw mechanism is commonly attached to it to achieve this. Such systems are known as motorised actuators.

Speed, Flexibility & Consistency Manufacturing sectors are looking at how to maximise the use of existing and new machines in the production floor; linear actuators are tasked to achieve faster and consistent results from each movement to meet the desired output. For example, to move a short distance of 50mm in 0.5 seconds – and to achieve this consistently.

Moreover, it may also be necessary to increase the flexibility in positioning, where multiple positions can be achieved – instead of only forward-and-return motions that are usually achieved by pneumatics or hydraulic actuators. Linear mechanisms can be employed with a stepping motor to create this motion, using pulses to control every motion precisely, achieving the desired positioning time at different distances.

Figure 1 demonstrates the requirements for setting up a stepping motor with a ballscrew mechanism: • Select the required ballscrew, suitable guide, coupling, bearing support and size of motor • Design of the work table, base plate and drafting of all required components • Order and fabrication • Assembly, fine tuning and testing

26 industrial automation asia | Oct/Nov 2010

Going Easy

With Motorised Actuators

Equipped with the latest technological features, actuators offer convenience for the machine manufacturer, the production floor and maintenance personnel. By Charles Lim, customer support centre manager, Oriental Motor Figure 1: The different components for a motorised actuator

Figure 2: Example of a motorised linear slide construction

On the technica l a spects of the setup, the following are concerns:

Figure 3: The ELS6XD is able to move a 30kg load

• Lack of knowledge or experience in selection and assembly • Difficulty in managing bill of materials; items may have different lead-times • Labour cost from selection to assembly and test • Consistency (may produce different quality of assembly) Ready For Assembly Pre -assembled actuators are available, where the stepping motor ha s a lre ady been assembled with a ballscrew, belt and pulley or rack and pinion mechanism. A pre -assembled ba llscrew mecha nism setup as shown in Figure 2 has the following benefits: • Selection of motorised actuator is easy; based on transportable mass and speed.

• E a s y p a r t s m a n a g e m e nt , drafting is simple using the ava ilable Computer A ide d Design (CAD) data.

• No assembly or fabrication of parts; setup time can be reduced significantly • Labour cost saved • Inspection is not necessary as specifications would have undergone qua lity control checks.

A range of motorised actuators are available to suit different needs.

For the budget conscious, the ELS series comprises of a simple setup

ENQUIRY NO. 183

• Value-added features such as adopting a closed loop feature and easy programming can be incorporated to achieve higher reliability and faster setup

Oct/Nov 2010 | industrial automation asia 27

control point

Figure 5: Programming mode display using the MPC10

Figure 4:The console can store different speed and direction positions

The Limo range can also be programmed to provide a push force at standstill

of a closed loop stepping motor ballscrew and guide assembly, encased within an aluminium frame. The motorised linear slide ELS6XD can move a load of 30kg to a position of 300mm within 0.92 seconds, and achieve a repetitive positioning accuracy of Âą0.02mm (Figure 3).

The closed loop stepping motor employs a Magnetic Reluctance (MR) encoder which ensures reliability like a conventional servomotor. It prevents missteps in positioning, and provides useful signals, such as an alarm output to inform the user of any possible abnormality.

The Brainwork For the control of the limo m o to r i s e d l i ne a r sl ide s o r cylinders, it adopts the EZ-Drive system, which is available in two types of drivers: The Pulse 28  industrial automation asia | Oct/Nov 2010

input, and Positioning (built-in controller) types. The Pulse input type driver is suitable in systems where positioning runs on the pulse number and speed provided by an external controller, such as directly from the Programmable Logic Controller (PLC) which offers pulse output control.

This conventional method requires the setting of pulse number, pulse speed, direction and acceleration to be calculated a nd progra mmed for the controller. More wiring may be needed when the controller is separate from the PLC. For ease of use, the positioning type driver has an in-built controller ready, where it can be programmed using a MPC10 programming console (Figure 4) for 31 programs which can store different speed and direction positions (Figure 5). Since programming can be

performed in the driver, the PLC programming is easier; it simply uses general I/O control to select the required program and provide the start signal to execute.

Compared to the conventional way of developing drivers, the drive positioning driver offers six input and six output signals, which is developed to have Variable Layer I/O (VLI). It can be customised to meet the different needs of each system either by using the programming console or software. This can reduce the cost of the driver, where unnecessary signals do not have to be within the circuitry of the Printed Circuit Board (PCB) and hence also create a more compact size.

The EZ Limo range is also available with the motorised cylinders ELC series – where other than achieving multiple positions, can also be programmed to provide a push force at standstill. The conventional way of achieving this is normally by using pneumatics, where the desired push force is achieved by adjusting the air control valves.

An identical result can be obtained with motorised cylinders where the push force can be set (ie: 10N) in the positioning driver, along with the required push distance and speed using the programming console. When the motorised cylinder executes the push motion, it automatically adjusts the output torque of the stepping motor by limiting the output running current.

No manual adjustments are needed and different push parameters can be set in different programs, ready to be selected by the PLC accordingly, whenever required.

Maintenance Made Easy For motorised actuators that are used intensively in the machines of production floors, issues such as temperature rise may occur in the motor and driver. Preventive maintenance is commonly practiced

in manufacturing, and the drive system is designed to allow real-time monitoring, such as tracking the motor and driver temperature using the programming console.

To preve nt dow nt i me , it can be configured to provide a warning signal when the motor or driver temperature hits a certain threshold, before it actually triggers the alarm output (which may abruptly stop all operations).

Providing a warning signal allows ample time for corrective action, such as triggering the operation of a cooling fan that can reduce the temperature; while doing so, it does not stop the operation of the motorised actuator, hence reducing downtime.

For actuator systems, mecha nisms w ill eventua lly reach their end- of-life due to rolling fatigue, and will require

replacements. The estimated lifespan of a motorised linear slide can be approximately 5,000 km; however most users are unable to monitor how far it has travelled during production or determine replacement time.

T h e d r i v e s y s te m h a s a feature whereby the motor has an in-built CPU that records the travel distance in memory. By using the programming console, one can easily view the actual travelled distance and consider preventive maintenance when r e q u i r e d . M o r e o v e r, i t i s possible to set a mechanical life distance warning output so that it will inform the higher controller automatically, once the travel distance threshold has been reached – bringing ease of monitoring to the user.

The driver is equipped with

Ad_Industrial_Automation_print:Ad_Industrial_Automation

24.06.2010

automatic recognition technology and hence only one type of driver is required for standby (in case the existing driver fails), as it can adjust its parameters automatically when connected to any motorised actuator.

Motorised actuators that are equipped with the latest technological features, provide convenience for the machine manufacturer, the production floor and the people maintaining the machines. In future, instead of concentrating on how well or quickly an engineer is able to set up a motor with a mechanism, the point-of-focus can be on how to utilise the benefits of preassembled actuators to their machine advantage, and to develop more user-friendly features.

16:40 Uhr

Seite 1

ENQUIRY NO. 7301

Intelligent Electronic Circuit Breaker (ESX10-T) for Process Field I/O, Automation and Machine Building � Precise and Instantaneous Fault Detection � Remote Status Indication � Suitable for Long Cable Systems � Remote Controllable � Eliminates Power Supply Failure � UL 1604 (Class I, Div. 2) � Modular 12.5 mm wide � 0.5 to 12 A at DC 24 V Please contact Ms Leo Li Leng/Ms Zoann Lau to understand how ESX10-T optimizes your process: E-T-A Asia Pacific Pte Ltd . Phone: +65 6841 4484 . E-Mail: info@e-t-a.com.sg . www.e-t-a.com.sg

ENQUIRY NO. 144

Fuse is history ESX10-T is the future

Oct/Nov 2010 | industrial automation asia 29

control point

T

oday, there are about 62,000 compressed air systems at work in German production plants alone – tensioning, clamping, moving and handling workpieces. Globally, there are several million users who benefit from compressed air technology that is easy to handle and install.

However, the more pneumatic drives and valves that are required to control machines and systems, the bigger the jumble of cables and tubes. Every single valve needs an electrical connection and each solenoid coil is wired individually to the control system. Silencers, compressed air supply, fittings and the corresponding tubing connections for the working lines need to be connected to the cylinder.

This problem was first solved with a manifold valve assembly, which put several individual valves together. However, it was only with the invention of the valve terminal t hat pneumatic insta llation technology was revolutionised, as conventional electric wiring and pneumatic tubing were highly timeconsuming and cost-intensive. In 1987, one of the world’s first valve terminals was presented under the name ‘Type 01’.

30 industrial automation asia | Oct/Nov 2010

Pneumatic Valves:

Strength In Application

Having undergone constant improvements, valve terminals offer a host of functionality in a compact size. By Christopher Haug, Festo Its successor, the sturdy tiger valve terminal Type 02, has been on the market since 1989 and has applications in the automotive industry where reliable, almost indestructible pneumatic control systems are needed. Type 03 was a modular valve terminal. Modular valve terminals can be extended or decreased in size.

Miniaturised Assembly With compactly constructed valve terminals, on the other hand, the number of valve positions cannot be changed. However, these have the advantage of being comparatively small and compact despite their high power density, a and can therefore be installed near the drives in the middle

of machines and systems. This makes it possible to keep the tubes and cables relatively short and to improve the efficiency of the compressed air. Since 1996, the Compact Performance Valve (CPV) terminal has been a choice for handling and assembly technology, and also for many other industrial applications.

Since 2001, this compact valve terminal has also been available in a miniature version, the CPV-SC (Smart Cubic), which is used in the electronics and light assembly industry, for example, integrated in mobile phone testers. Special industrial valve terminals such as the corrosion-free, easy-to-clean Clean Design Valve terminals Type CDVI complete the product range

Integrated Control Special technology modules are integrated into the electrical terminal system for controlling motion, safety and diagnostics f u nct ions. T his save s bot h installation and operating time and costs. For example, the electrical terminal can function as a standalone I/O system with an integrated control unit, as individual modules enable communication from the simple gateway function to the front-end control in the machine in IP65. With a CoDeSys fronte n d c o n t r o l l e r, t h e d i r e c t machine assembly has its own control system, which reduces installation costs and allows preprocessing or even completely stand-alone control.

Electric multi-axis controllers in the form of electrical terminal modules control up to 31 electric drives as individual axes or up to eig ht sy nch ronou s a xe s

with interpolation in 2.5 D via CANopen. There are also modules for proportional pneumatics and servopneumatic applications. The electric end-position controller Soft Stop, ensures 30 percent shorter cycle times and 30 percent lower air consumption, due to fast, impact and vibration-free travel between two fixed stops. Another

module which can be integrated into the electrical terminal is the ser vo -pneumatic positioning controller for pneumatic drives.

In addition to controlling pneumatic and electrical move me nt s, t he f u nc t io n a l integration of modular valve te r m i n a l s i s a l so bre a k i n g into t he field of me a sur ing

ENQUIRY NO. 175

for these central control units for pneumatic automation technology.

One of the latest highlights in valve terminal technology is modular valve terminals combined with an electrical terminal such as the CPX/MPA. Its strengths: the modular design of the valve terminal MPA with high power density, combined w ith the electrical terminal CPX. This makes it possible to integrate many functions, including control for motion, safety and diagnostics.

Electrical terminals are suitable for use with common Fieldbus and Ethernet systems, as well as company-specific installation standards. A choice of three installation concepts – centralised, decentralised and hybrid – reduces cycle times by up to 30 percent and air consumption by up to 50 percent. The extensive integration of pneumatic, electric and motion functions reduces system costs by up to 20 percent and installation time by up to 60 percent.

Oct/Nov 2010 | industrial automation asia  31

control point

With diagnostic features with flow and pressure sensors, condition monitoring in pneumatics is already possible

and regulating pressures and temperature. Measuring modules turn pneumatic cylinders into sensors which save time and space: they extend and retract in just one work step, performing measurements at the same time.

Integrated pressure measuring modules with four pressure s e n s o r s re pl a ce i n d i v idu a l sensors in the field. Modules for temperature sensing for four thermoelements and resistance sensors allow on-site solutions to IP65. This saves space and reduces installation time.

The va lve termina l V TSA can also be combined with an electrical terminal. The valve terminal enables users to mix four different valve sizes. Even more important is the safety functions of the terminal, which match performance level PL d and provide solutions for: • Protection against unexpected start-up via switchable pilot air • Reversing • Exhausting • Disconnectable pressure and voltage zones 32 industrial automation asia | Oct/Nov 2010

The FinGripper – inspired by nature, built for nature: the gripper fingers can adapt to the contour of a workpiece with pressure applied at the side – similar to the human hand, but faster.

The automation platform CPX with remote I/O and valve terminals, can be used for customised solutions, such as control cabinets or preassembled systems. They are part of a completely preassembled subsystem which helps the user save time and costs in design and assembly. The modular design means that it is even possible to have up to 512 I/O per Fieldbus node. This enables the user to mount 128 solenoid coils and up to eight additional power supply modules for pressure and voltage zones.

With diagnostic and preventive ma intena nce f u nc t ions, t he electrica l termina l helps to increase machine availability. It supports module and channelspecific diagnostics such as undervoltage identification at outputs and valves, short circuit detection for sensors and valves and open load detection when a solenoid coil is missing.

The ability to set diagnostics is still combined with the memory function – the electrical terminal

saves the last 40 fault causes with the beginning and end of the fault. This makes it easier to locate the causes of faults in the electrical installation quickly. Combined with flow rate and pressure sensors, the terminal can form condition monitoring solutions.

Mechatronic Assembly I n t he f ie l d o f au to m a t io n technolog y with pneumatics, mechatronics is not only restricted to the control side – it can also be used on the actuator side. Electric drives can be added to the pneumatic drives in modular mechatronic handling systems. The electric drives have the same geometries and interfaces as their pneumatic cousins. This creates an almost limitless number of combinations for handling solutions – servopneumatic, electric or a mixture of both, in order to fully exploit the advantages of both drive technologies. The trend is moving towards customers ordering c o m p l e te l y p r e - a s s e m b l e d handling systems and modules.

Tested in advance, delivered with all design data and circuit diagrams, pre-assembled handling systems bridge the gap between idea and machine and reduce the number of interfaces. Complete solutions allow convenience for technical personnel, while the complexity and cost of design are kept low. Preassembled handling systems make the procurement process simpler and reduce process costs – due to single sourcing and order processing using a single part or project number.

This includes the integration of vision systems – for setting up production processes or quality assurance.

to the bands via joints, are installed at regular intervals. With this flexible joint, the gripper fingers can adapt to the contour of a workpiece with pressure applied at the side – similar to the human hand, but faster.

Gentle Strength The bionic grippers can be used in a sorting station for small, hollow chocolate eggs. The gripper fingers wrap all the way around the contour of the chocolate egg without crushing it or damaging its aluminium foil packaging. “The flexible structure makes it possible to grip the eggs when they are at an angle or incorrectly positioned,” explains Federico Nardone, an engineer from Italian system integrator, FluidoDinamica.

A proportional valve such as the VPPM ensures that the

ENQUIRY NO. 167

Inspired By Nature Bionic systems offer an interesting perspective, converting motion sequences and designs from nature into technology. The first step was

the success of grippers such as the FinGripper in handling fresh fruit, bulbs and pressure-sensitive foods quickly and safely. This is made possible by the ‘Fin Ray’ effect, which was based on the design of a fish’s tailfin.

Gripping and handling tulip bulbs and soft chocolate eggs using conventional grippers made of metal or using a vacuum function incurs losses and damage to goods.

This impairs two of the central aims of automation technology: speed and quality.

The bionic FinGripper, on the other hand, is light, flexible and adaptable. It comprises a pneumatic actuator in the form of a bellows and three gripper fingers like the tailfin of a fish. The basis of this structure is two flexible bands which come together to form a triangle at the tip. Intermediate struts, connected

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control point

correct amount of pressure is applied. This makes it possible to travel individual acceleration and pressure ramps. Variable flow rates in the proportional valves adjust the cylinder pressure to the production or sorting process.

This is networked with a robotic controller such as the CMXR, w h i c h co n t ro l s t h e t r ip o d robot handling unit. The tripod quickly moves the gripper to the chocolate eggs. This robot type is ideal for handling light loads at high speeds.

The gripper is manufactured using selective laser sintering.

Layers of polyamide powder measuring 0.1mm in thickness are applied one after the other and hardened to a fixed component.

This reduces the weight on the toolholder by 90 percent compared to a conventional metal gripper, allowing the gripper to grip and move in a more energyefficient manner.

The Netherla nds-ba sed company Total Systems also uses the advantages of the light, adaptive bionic gripper to create machines and systems for processing flowers and flower bulbs. The gripper was used in the the development of a flower bulb sorting machine. The

In 1987, Festo's first valve terminal was presented under the laconic name ‘Type 01’

company uses the gripper to sort flower bulbs according to size and quality. What was previously painstaking, inefficient, manual work is now performed by the gripper.

Experts predict a rosy future for automation using pneumatics.

This is due in no small part to revolutionary drive concepts such as the fluidic muscle and mechatronic system solutions which combine pneumatics, electronics

and software. The integration of microprocessors into cylinders and valves creates intelligent pneumatics – the development of bus technology is a boost for this process. Advances have also been made in miniaturisation, meaning that the overall size of a directional control valve today is only seven percent of what it was in 1961.

ENQUIRY NO. 7302

Electrics vs Pneumatics Pneumatics and electrics are not mutually exclusive. On the contrary – it is simply a question of requirements.

There are advantages in using pneumatic drives: they are robust when faced with harsh ambient conditions such as dust, oil, water or cleaning agents; they are durable, easy to install and offer exemplary handling. They are inexpensive and easy to handle. When fitted with the corresponding sensor and valve technology, pneumatic systems also take on the characteristics of drive technology – the capability to position freely.

34 industrial automation asia | Oct/Nov 2010

When there is a rapid build-up of force or when precise positioning is required, electric drives, for example with a servo motor, have an advantage.

In such cases, they are a choice for precision, constant speed, adjustability, defined positioning programmes and stability under load. Pneumatic drives can also be supplemented by electric linear, spindle and toothed belt axes and even multi-axis solutions, as well as geared, servo or stepper motors with controllers and position controllers.

The important point for the user is that it should be possible to

find the correct drive technology in terms of cost and performance for every task or application, and that all components perform their functions in a straightforward and reliable manner.

When all of these components come from a single source and are mechanically compatible, the question of ‘electrics vs pneumatics’ becomes irrelevant. The answer is pneumatics and electrics – implemented in mechatronic, modular systems for handling and assembling technology that, depending on the application, combine both in a suitable solution with plug and work.

software & Networks

AStrategyOf

PLM:

Sustainability

In a sea of increasing costs and constant change, manufacturing companies have to adopt the right practices in Product Lifecycle Management (PLM) to stay afloat. By Rama Tiwari, director, Autodesk South East Asia

T

he business world is u ndergoing a per ma nent change. This is particularly evident in the manufacturing i ndu st r y. T he cost s of raw materials are rising steadily, energy prices are escalating, and the global problem of waste management is becoming more acute.

Asia, as the manufacturing hub of the world, is at the centre of these changes. Although some

may feel that this exposes Asian manufacturers to greater risks and challenges, it also presents opportunities to identify ways to reap the benefits of sustainable manufacturing.

Design Matters Sustainability is usually defined as ‘meeting the needs of the present without compromising the ability of future generations to meet their own needs.’ The sustainability

of a manufacturer is measured by the impacts of its operations and its products throughout their lifecycles – from the stages of design and conceptualisation, all the way through to production, use and retirement.

One way for a manufacturer to become sustainable is by using less energ y and water during production while reducing material wastage. This is not a lway s prac t ic a l g ive n t he Oct/Nov 2010 | industrial automation asia 35

software & Networks

Software for digital prototyping enables manufacturers to digitally design, visualise, and simulate the future performance of their new products over their entire life cycle

resource intensive nature of the manufacturing process. Another way to become sustainable is to modify production processes.

However, this could result in adde d cost s of pro duc t ion f r o m d ow n t i m e , r e to o l i n g , worker retra ining, sof t wa re customisation, and safety and performance testing.

Two key factors can help to reduce the risk of updating a production process to improve its sustainability – one is by using a proven methodology and the other, a proven technology.

L e a n Ma nu fac tu r i n g a nd SixSigma are process improvement methodologies that target waste elimination to drive profitability.

A sustainable design methodology that borrows key elements from Lean Manufacturing and SixSigma may help a producer to target areas for improvement efficiently and effectively, with minimal risk.

However, such methodologies only lower operating expense 36 industrial automation asia | Oct/Nov 2010

w it hout incre a sing top - line revenue. To achieve the latter, manufacturers must innovate – whether with new product lines, ways to generate incremental revenue from existing products, or methods to deliver better quality to customers.

One way for businesses to increase their top-line revenue is to leverage design software innovations. By leveraging the power of digital prototyping, manufacturers can make better decisions in the early stages of product development, when they are most effective.

Fo r e x a mp l e , l e v e r a g i n g Inventor software for dig ita l protot y ping enable s m a nu fa c t u r e r s to d i g i t a l l y design, visualise, and simulate the future performance of their new products over their entire life cycle, improving speed to market and cost-effectiveness.

This makes manufacturing more sustainable by decreasing the

number of physical prototypes required and reduces operational waste – enabling manufacturers to create more sustainable designs that are easier to manufacture and recycle at the end-of-life.

Optimal Approach Product design affects every stage of a product’s lifecycle – from conceptualisation to use, customer sat isfact ion a nd a f ter- sa le s support. Design is therefore a key influencer in ensuring sustainable desig ns through resource efficiency, carbon neutrality and emissions reduction.

For example, while motorcycles are generally more fuel-efficient than cars, they indiv idually represent a higher emissions burden. This is due to the lack of the widespread emissions reduction equipment, that are found in modern ca rs. New motorcycles can produce up to 15 times more emissions per mile compared to a new car or SUV.

Mission Motors has partnered with Yves Béhar (who worked on the One Laptop per Child project) to design an optimised, sustainable motorcycle with the help of 3D design software. Designed in one year, the zero-emissions motorcycle combines performance with leading industrial design, offering a range of 150 miles (241 km) per charge and a top speed of 150 miles per hour.

As 3D digital models are digital prototypes of the product, they allow a designer to consider material attributes such as weight, strength and recycled content, and process attributes such as energy intensity and water consumption.

By using digital prototypes, designers and manufacturers can experiment with alternatives that might achieve the desired sustainable goal without the need for intermediate physical prototypes to reveal the most feasible and cost-effective options.

Sustainable product outcomes and strategies will vary widely according to individual business needs, constraints and market opportunities. Examples might include: · Facilitating quick disassembly and recycling · Lowering energy use · Enabling fast, cost-effective remanufacturing by using only standard, interchangeable parts; and

Big Toys makes sturdy and durable steel and plastic play structures from 100 percent recycled materials.

· Substituting ex isting raw materials with recycled or recyclable materials An example of substitution with recycled materials is BigToys.

They are a commercial playground equipment manufacturer that makes sturdy and durable steel and plastic play structures from 100 percent recycled materials.

To design its equipment, the co m p a n y r e l i e s o n d i g i t a l prototyping solutions to create safe, sustainable playgrounds for children across Asia. Their equipment has been installed in public areas including Vivo City (Singapore), Desa ParkCity Central Park (Malaysia), Trinoma Mall (Philippines) and Da Nang Park (Vietnam).

Put On Trial Re ga rd l e s s o f t he sp e c i f ic sustainable product outcome and strategy selected, a digital prototype will save the design and manufacturing teams time and money as it analyses and tests alternative options. In many cases, the digital prototype will be able to predict the impact of the proposed change on the product’s characteristics and the energy consumed during its manufacture.

Armed with such data, the design and manufacturing teams

can quickly and cost-effectively experiment with different material and process variables until they discover the optimal combination to meet var ying market and regulatory conditions.

The digital prototype can also be used to simulate stress a n d p e r f o r m a n c e te s t s to facilitate compliance with safety standards, or to predict energy consumption and environmental impact throughout the product’s lifecycle. Rather than building physica l protot y pe s, t he optimised design can be tested a nd broken v ir tua lly before spending on materials or labour.

While it may still be a competitive differentiator today, sustainability is becoming an expectation of doing business in the global economy.

A sustainable approach reduces risks at every stage of business.

It helps ma nufacturers a nd businesses to reduce exposure to the possibility of material shortages, energy price increases, or higher fees for waste disposal. With 3D design, designers are able to develop products that meet one or more environmentally sustainable, yet business-driven outcomes. In today’s changing world, sustainable manufacturing is helping to drive competitive advantage, profitability and growth.

ENQUIRY NO. 7401 Oct/Nov 2010 | industrial automation asia 37

instrumentation & Measurement

Vibration Analysis Training:

E-Learning vs

The Classroom

Imparting skills for vibration analysis and certification.

Is one approach better than the other? By Bill Slonaker, Mobius Institute

S

oftware tools can make vibration analysis training more interesting, fun and effective. If a picture is worth a thousand words, how much is an animated, realistic 3D model of a machine worth to teach something as difficult as vibration analysis for machinery condition monitoring?

Interest In Learning iLearnVibration, a computer-based training program, 38  industrial automation asia | Oct/Nov 2010

uses Computer Aided Design (CAD) machinery drawing software programs to create realistic models of actual rotating machinery – that are typically found and monitored in most plants. To make them more visually interesting, they have been created in 3D, using transparency tools.

To make them more educational, they have been animated and exaggerated to show the relative movement created by machine faults. The animations

Figure 1: The iTeachBearings simulator

The advantages of e-learning programs are many.

There are multiple types: software applications that are installed on a computer, online systems that require an Internet connection, and video-based systems that can run on a computer or TV disc player.

Learners are able to work at their own pace. Many people can absorb a certain amount of information at a sitting, but then need to let it sink in, before putting it to use.

They may need to focus on it for a bit, try new settings in a data collector, for example, and see how it affects what they see in their condition monitoring software and compare it to historical data. This

Imparting Skills Classes are taught globally in many different languages and comply with ISO and ASNT requirements for certification for Cat I, II and III, and Levels I, II and III respectively.

ENQUIRY NO. 172

are linked to vibration spectra that are used by analysts to monitor and diagnose machine problems.

Some even allow the learner to fly around the machine and explore various views. Others let the learner select faults and adjust the severity while watching the vibration spectra change in an adjacent screen.

This has led to development of a library of machine models and simulators, much like the traditional test rig, where machine faults could be created in software, animated and the resulting signals created. These could then be fed into a data collector for analysis by the person taking the training, creating a realistic training scenario.

Figure 1 is a screenshot from a simulator called iTeachBearings. It shows a rolling element bearing with defects: at the bottom of the outer race, at eight o’clock an inner race defect, and a ball defect at two o’clock.

The screen to the right shows each component of vibration as separate time waveforms: the outer race and the ball defects are active, so the shaft speed is the low frequency sine wave, and demodulation occurs as the ball defect moves in and out of the load zone of the bearing.

The instructor or learner can choose among several defects to activate, adjust the speed of the shaft, increase the severity of the defects and observe how the time waveform signals on the right change in response.

The screen on the right also turns on its vertical axis to go from showing a time waveform, to an FFT spectrum. Each vibration component is seen separately, visually displaying how a complex time waveform signal contains each of the vibration components. The FFT displays them in a more understandable format.

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instrumentation & Measurement

integrates the new information with what they already know, and they do not need to go back and review or learn it again for an examination. This usually is the way that people typically work and learn naturally.

E-learning lets learners work at times and places that fit within their busy schedule. They may not have time at work to study vibration analysis, but may feel that it is important to their career development.

Or they may want to become certified as a vibration analyst. E-learning allows them to work at home, or both, being completely portable between computers.

Time Flexibility Many do both, having short periods at work in which to study and being able to log on to the same system from home during off-hours. Many companies also have corporate learning management systems that allow managers to schedule training for their personnel and monitor their progress.

The biggest advantage to e-learning is probably the cost. The old axiom holds true: you get what you pay for. There are many inexpensive training programs available, but the good ones cost more.

Some e-learning programs are only a few hours of information and do not go into enough depth to really cover the topic.

If a course that takes four days to teach in a classroom is reduced to only a few hours of instruction as e-learning, the two are not that comparable. However, even the most expensive e-learning training program is less costly than the total cost of sending someone off to a week of

instructor-led training and paying for airfare, hotel, meals and perhaps a rental car.

Based on these considerations, why would anyone attend a traditional course that is led by an instructor?

As a start, it is a combination of factors. An experienced instructor can make even the most boring topics interesting and fun to learn. If the instructor has good stories and examples to share about specific ‘learning’ moments, it makes for a memorable course and trainees learn a lot. There is also the give and take between the trainees in the room and the instructor. So there is much value in the traditional class environment and some of it is unpredictable.

The instructor needs to be experienced, engaging and be willing to diverge from his or her planned discussion to deal with specific questions. They also need a library of tools to turn the question and answer into a learning moment for everyone in the room.

Whiteboards are fine if the instructor is skilled as an illustrator and quick on his feet.

Tools For Use Based on the development of iLearnVibration, a software toolkit is available for the instructor that allows him or her to jump into this new topic completely, illustrate the issue with animations and simulators from the software library and make it a part of the course. If handled well, this type of give and take between the class and the instructor facilitates teaching and learning events.

A detailed model of a motor with cooling fins, windings and rotor bars

A wind turbine generator planetary gearbox, low detail, used in an animation of a wind turbine machine train

40  industrial automation asia | Oct/Nov 2010

Qualification Requirement Certification for vibration analysts is important and it is recommended that personnel who work in facilities with critical rotating machinery should be certified to perform vibration analysis.

Most vendors of machinery condition monitoring instrumentation and software provide training for their products. This is usually good training in the proper use of these products, but just touches on the information

that is produced by these systems. It is assumed by the vendors that the personnel using the former’s products are experienced engineers and technicians who completely understand vibration analysis.

Machinery condition monitoring is still a relatively young field that is taught in just a handful of universities, so most people in the field have learned through direct experience or via additional training outside of academia.

The ISO, ASNT, BINDT and others have created standards for the allowable vibration levels for various types of machines. They also have standards for the training, testing and certification of personnel who will be working in this field. Not only is there valuable equipment at risk, but there is often a significant safety risk if monitored machinery is not properly diagnosed and maintained.

The transition from classroom or e-learning courses to sitting for a certification examination is also important. Having the opportunity to prepare online for a course and then take a classroom course with an experienced instructor is a good way to prepare.

There is a place for both e-learning and traditional classroom training. For vibration analysis and certification, it has been found that one of the best approaches combines both.

ILearnVibration is created by Jason Tranter, founder of Mobius Institute

ENQUIRY NO. 7501

ENQUIRY NO. 178

It is also important for everyone in a class to feel comfortable and be willing to ask the questions that lead to these teaching moments.

In some situations, adults are hesitant to ask questions because they do not want to distract the trainer, or do not want to expose their perception that they do not know as much about the topic as others in the room. But trainers and educators want these questions as it makes the class more interesting for everyone.

However, even w ith the most adva nced presentation tools and animations, it is still difficult for many people to absorb and retain the amount of information that is presented in four eight-hour days, even in the best classroom environment.

It has been found that by giving learners the opportunity to review the course materials online before the course date, the deficiencies of classroom training vanish. Learners are encouraged to take the entire course before they even attend the class.

This may seem redundant, but for people who have had less exposure to vibration analysis, it allows them to do some self-study to get a level of familiarity with the terminology and concepts. It also allows everyone to know what will be covered and each learner can work to fill in recognised gaps in their knowledge before they attend the course.

It has been observed that learners in classroom courses who have used this access ask more questions, ask better questions, and it makes for better instruction and more ‘ah-ha!’ moments for everyone.

Taking the course online in advance also spreads out the learning process over time, giving the learner more time to incorporate the information. As they go through the course, they have an opportunity to focus on areas that they found difficult.

They are prepared with questions that have come up as they have started to use this knowledge in their work and it makes the course more effective for them personally. Sometimes it is even possible for students to bring case history information with them, to use as a training aid for the class and to demonstrate interesting situations.

Oct/Nov 2010 | industrial automation asia 41

sector spotlight

Process Gas Analysers:

Sifting Out

Understanding the pros and cons of the various technologies that are available to the natural gas industry – and making a choice. By Michael W Markus, Sick Maihak

H

ydrogen sulfide (H 2 S) is commonly found in natural gas, biogas and other gases of organic origin. It is a typical by-product of the bacterial breakdown of organic matter under anaerobic conditions. Even low ppm levels of H2S are poisonous, corrosive, and produce the characteristic odour similar to rotten eggs.

Elevated levels can corrode compressors, pipelines and process equipment in the distribution or processing of natural gas and contribute to lower quality combustion, and the production of sulfur dioxide. Consequently, the maximum content of this undesired component is regulated in commercially sold gas and must be monitored and/or controlled in every stage of the distribution and processing of such gaseous fuels.

Process analyser equipment are therefore recommended to measure low levels of hydrogen sulfide in a matrix of various hydrocarbons and in the presence of varying contaminations like CO2 and moisture.

Kevin Abbott, US

42 industrial automation asia | Oct/Nov 2010

Setting The Stage Raw natural gas is collected from wells that are located close to underground oil or gas fields. At the collection point, free liquid water and natural gas condensate are removed before the raw gas is piped to a gas processing plant where the initial purification step is made.

This is usually for the removal of acidic gases like hydrogen sulfide, CO2 and/or mercaptans. Depending on its individual origin, raw natural gas can contain hydrogen sulfide in double digit ppm levels. Natural gas where the H2S content exceeds the level of 4 ppmv is called ‘sour gas’. Correspondingly, gas which does not contain significant amounts of H2S or where H2S has been removed to acceptable levels is called ‘sweet gas’.

Choice Of Technology Several types of process gas analysers which are able to detect low levels of H2S exist but must be chosen to match with the user’s expectations in terms of analytical performance and lifetime cost of the equipment.

Analysers based on electrochemical sensors that are commonly used in the biogas production appear to lack sensitivity and selectivity to be fit for purpose in the natural gas processing industry.

Additionally, electrochemical cells can suffer from fast aging and unpredictable and undetected failures. These can introduce the risk of damage to a pipeline, a process column or a catalyst in the downstream processing by an undetected breakthrough of sour gas.

A na lyser technolog ie s like proce ss Ga s Chromatographs (GCs) and the colorimetric analysers of the lead acetate tape type offer good sensitivity and selectivity. However, they require a significant amount of maintenance and result in considerable lifetime costs due to the need for operating supplies and/or consumables. Bottled calibration and carrier gases or reagent paper tapes are not easily available in some natural gas producing regions, which might place logistics demands on the end user of these technologies.

Tunable Diode Laser Spectroscopy (TDLS) has been introduced to measure low ppm levels of H2S in hydrocarbons. TDLS is known generally for its selectivity and stability but also for its elevated investment needs. The laser diodes are costly as they have to be selected carefully for the required detection wavelength and tuning characteristics.

The high initial investment in the technology is

compensated in part, if it can be operated in-situ. This would avoid the need for a sample and conditioning system, which is often responsible for the major part of the lifetime cost of an extractive analyser set-up.

Understanding Limitations Unfortunately, the low absorption levels of H2S in the Near-Infrared (NIR) spectral range as well as the operational regime of TDL, do not allow measurements in-situ, as several metres of active path length are needed to achieve the required sub-ppm detection limits.

This can only be achieved by relatively sophisticated extractive solutions including heated and corrosion resistant multi-pass sample gas cells. To establish a typical active path length of about 30 metres in a sample cell of reasonable dimensions, the laser beam must be reflected often.

In order to allow a stable operation of the multipass cell without the need for re-alignment over an extended period of time, a sophisticated optical design and a temperature-controlled operation are required – which have an impact on the overall system costs.

Additionally, the filters in the sample conditioning system must be efficient at all times.

After several reflections, even a small degradation of the reflectivity of the mirrors on the inside of the multi-pass cell due to a contamination, would have

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ENQUIRY NO. 171

Those processes within natural gas processing plants that remove acid gases are therefore commonly referred to as ‘sweetening’ processes. The removed H2S is normally then converted to by-products like elemental sulfur in a Claus process, or it can be treated in a Wet Sulphuric Acid (WSA) process unit where the by-product is sulfuric acid.

Depending on the individual stage along the transportation and natural gas processing path, the requested measuring ranges and conditions for the determination of the H2S concentration can be different.

In the raw and often sour gas at the feed stock of a natural gas processing plant, the H2S content is in the level of several ppm and above, which is then significantly reduced to trace levels in the sweetening process. At the sulfur recovery unit however, high vol percent ranges of hydrogen sulfide must be expected in the presence of high SO2 concentrations at some intermediate process steps.

Oct/Nov 2010 | industrial automation asia 43

sector spotlight

The two beam photometer design of the GMS800 Defor analyser can be identified by the two parallel flow cells behind the front panel.

The operation of the analysers at remote locations is supported by a remote control option which can incorporate any available digital communication link from Ethernet to GPRS.

a strong impact on the signal quality. Also, it might cause an unplanned shutdown of the analyser system for dismounting and cleaning.

For more than 60 years, Non-Dispersive Infrared (NDIR) photometers have been the analyser technology of choice for the detection of low concentration levels of infrared active gas components for the majority of process applications. The reason for this dominant market position is the favourable combination of good analytical performance and reasonable lifetime costs.

Finding A Fit For the same reason Ultraviolet (UV) process photometers can often be regarded as the best compromise for those gas components like H 2 S, having absorption bands in the ultraviolet spectrum.

Non-Dispersive UV (NDUV) photometers utilise the interference and gas filter correlation technique, which allow for sub-ppm sensitivities for UV active gas components like H2S, SO2, NO, and NO2.

Cross interference to water or CO2 can be neglected in the UV spectral range, which is an advantage for measurements in natural gas as it often carries some CO2 and moisture. Unavoidable cross sensitivities eg: of SO2 to H2S can be compensated for by simply measuring the SO2 concentration in a separate measuring channel.

The modern UV process photometer incorporates some features which make the NDUV approach even more attractive to H2S measurements in natural gas processing. It utilises a long-life UV light source based on an electrode-less discharge lamp which offers typically more than two years of operation before there is the need for an exchange.

44  industrial automation asia | Oct/Nov 2010

The optical design follows the principle of a true two-beam photometer. A 50 percent optical beam splitter splits the light intensity equally between the sample path and a reference path. Both of which consist of the same components: flow cell, optical windows, and silicon photo-detectors.

The signal of the reference path allows for compensation, eg: for noise introduced by the UV lamp even when the reference cell is filled with just air. Special compensation requirements can be taken care of by means of flowing reference gas. The gas cells as well as the complete sample gas path are kept at a constant temperature to avoid thermal drifts. As an option, it can be heated up to 100°C to minimise the risk of contamination by condensates.

The photometer is equipped with interference and/or gas filters according to required measuring ranges and other application needs. Under suitable conditions, up to three UV active gas components can be measured with a single photometer in parallel.

Two subsequent filter wheels are used for the correlation of on-band and off-band positions in the active spectral range. The filter wheels are mounted in an enclosure and are kept at constant temperature by means of an active temperature control to avoid any thermal effects on the filters.

An optional filter wheel behind the gas cells in front of the silicon photodiode detectors allow for an automated zero and span adjustment at any time during operation.

In doing so, the need for a calibration or validation with test gases can be reduced significantly. The instrument can be operated hands-off for more than six months without the need for calibration with test gases.

From A Distance The operation of the analysers at remote locations is supported by a remote control option which can incorporate any available digital communication link from Ethernet to General Packet Radio Service (GPRS).

The instruments in an analyser network can be identified by their individual IP address and can be addressed for parameterisation and/or for diagnosis from any PC using the free SOPAS ET configuration SW tool. This feature is useful for remote measuring points, onshore and offshore, where the possibility of on-site inspections and manual adjustments is rare.

H 2 S is a common but undesired component of natural gas, due to its unfavorable properties.

Therefore, H 2 S content must be monitored and controlled at various stages of the gas sampling, processing, and distribution. A UV photometer is a good choice for the detection of low ppm levels of H2S in natural gas as it offers a good analytical performance at reasonable cost.

Cross interference to hydrocarbons, CO2 and water – the major components of natural gas, can be neglected in the UV spectral range. Modern UV analyser designs allow for automated and maintenance free operation for several months without the need for any manual adjustments.

The requirements for consumables and other operational supplies are significantly reduced if compared to competing technologies, which results in low lifetime service efforts for the end-user. The wide operational range of the UV photometry for H2S detection from ppm levels up to 100 Vol percent, the option for a remote operation and the ability to run hands-off for an extended timeframe makes this type of analyser attractive for the natural gas industry. This is because the facilities are often situated at remote locations and are operated by minimum staff.

ENQUIRY NO. 7601

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ENQUIRY NO. 079

Scope Of Measurement The UV analyser offers a smallest measuring range of 0-25 ppm H2S but can also be configured for ranges up to 0-100 Vol percent. Therefore the UV photometer can be used at the most of measuring points for H2S across the natural gas processing from raw gas feedstock down to sweet gas. Cross interferences to other sulphur-containing species in the gas like COS or mercaptans must only be considered if these interfering species are present at certain levels in the H2S concentration.

The sensor module of the analyser, ie: the UV photometer itself, operates independently of the individual analyser housing which only acts as the enclosure, and the user and data interface, respectively.

The sensor module itself comes fully calibrated and delivers concentration values to the analyser via an internal Controller Area Network (CAN) bus.

The internal communication of the individual sensor modules with the user/data interface is standardised within the analyser: this analyser family consists of sensors modules of various physical principles like NDIR, NDUV, paramagnetism, and TCD, and offers different types of enclosures for 19 inch rack and wall mounting. This allows a versatile approach for multisensor analyser units and systems.

The individual sensor modules can be mounted inside a standalone 19 inch rack mounted analyser, in an Ex d or Ex p wall mounted enclosure for operation in hazardous areas, or in an analyser system cabinet, in any combination. A single analyser enclosure can carry up to three sensor modules which communicate via the internal CAN bus with the Human-Machine Interface (HMI) of the stand-alone analyser unit; or with a System Controller Unit (SCU) managing a complex analyser network, respectively.

The data communication towards the end customer’s Distributed Control System (DCS) can be configured to match with any available standard including Ethernet, Modbus, OPC, and Profibus.

Analogue and digital I/Os are available as well.

Oct/Nov 2010 | industrial automation asia 45

energy

Creating Energy From Waste T

he consumption habits of modern consumer lifestyles are causing a global waste problem. The UN and other agencies estimate that worldwide, more than one billion tonnes of waste are produced annually, and some estimates go as high as 1.9 billion. France-based Veolia Environmental Services estimated an annual world output of 3.4 – 4 billion tons of solid waste.

Of this, only around one billion tons is thought to be recycled, composted or used to produce energy.

Pollution Control Wa s t e - t o - E n e r g y ( W t E ) processes can help reduce the amount of waste entering the environment by conver ting energy in the form of electricity or heat from waste sources.

According to the International Solid Waste Association (ISWA) there were 431 WtE plants in Europe in 2005 and 89 in the US in 2004. These include plants that burn Refuse Derived Fuel (RDF), produced by removing

46  industrial automation asia | Oct/Nov 2010

re c y c l a b l e a n d u n b u r n a b l e wastes from solid wastes, and shredding and dehydrating the remaining organic fraction to a uniform fuel.

The most common WtE process is incineration, in which the combustion of organic material in waste is used to produce heat and drive steam turbines.

Combustion reduces the volume of waste ultimately disposed by 90 percent or more, significantly conserving landfill capacity and saving costs for cities.

Because incineration avoids land use issues associated with landfilling, it allows populated areas to avoid long-hauling of waste for disposal in remote landfills. The strategy of incinerating waste to recover energy has been the main waste management policy for many land-scarce countries, including Singapore and Japan.

In Singapore, 98 percent of all wastes are incinerated at four WtE incineration plants. Its newest plant, built and designed

by Keppel Seghers, is smaller

John Nyberg, Denmark

Technologies are available that can effectively convert discarded waste into a sustainable source of energy.

By Augustine Quek

than its predecessors with a capacity of 800 tonnes per day.

One of the design features of the plant is the combustion grate configuration.

This allows the effective mixing of waste for efficient combustion through a mix of slats within the grate, some of which are fixed and others capable of moving the waste in either one or two dimensions.

Other features include the water cooled multi-stage grate design, the boiler and the double dry flue gas treatment system. The single electricity generator can produce a maximum of 22MW from the incineration of solid waste daily.

Ideas In Action Japan, being the largest user in thermal treatment of Municipal S o l i d Wa s t e ( M S W ) i n t h e world with 40 million tons, has developed several methods.

The Ebara TwinRec process at Aomori is a combined material and energy recover y facility that uses shredder residue and

Magstefan, Austria

sewage sludge. It separates ferrous and non-ferrous metals and transforms ash into glass granules in a fluidized bed g a s i f i e r, w h i l e b u r n i n g t h e combustible portion to produce energy.

Based on the success of this procees, Ebara and UBE have jointly developed the EUP process to generate syngas – a kind of combustible gas, from plastic waste, while also recycling metals and glass granulate. Similar to the TwinRec process, it operates at higher pressures in a two-stage pressurised gasification and slagging system.

The Thermoselect JFE waste g a s i f i c a t i o n a n d re f o r m i n g technology process in Chiba is another flexible process that can recover energy from a variety of industrial wastes including waste plastic, sludge, wood chips, waste paper etc. Wastes are compacted without pretreatment, followed by drying and pyrolysis by indi­rect heating in the degassing channel.

Helbio, a Greek subsidiary of Sweden’s Morphic Technologies, has introduced a system for converting biogas from sewage into electricity and heat. In the system, biogas is converted into hydrogen using a Helbio reformer before being fed to a fuel cell manufactured by Morphic’s Italian subsidiary, Exergy Fuel Cells. The company claims that the hydrogen generated is sufficiently pure to run a fuel cell without contaminating the membranes and catalyst, and have decided to launch this combination of energy systems for wider applications in Europe.

Fulcrum BioEnergy has a two-stage process that converts municipal solid waste into ethanol.

It is currently building a WtE plant near Reno, Nevada in the US. The plant is scheduled to open this year under the name of Sierra BioFuels.

BioEnergy predicts that the plant

Waste-to-Energy (WtE) processes can help reduce the amount of waste entering the environment by converting energy in the form of electricity or heat from waste sources.

will produce approximately 10.5 million gallons per year of ethanol from nearly 90,000 tons per year of MSW. Other Methods In addition to the thermal treatment of waste to obtain energy, nonthermal systems also exist, mainly through microbiological processes, such as anaerobic digestion or fermentation to produce fuels like biogas or ethanol. Landfill gas recovery is one such method.

The Suzhou Qizi Mountain Landfill Gas Recovery Project in China is one example. The 5 MW landfill gas-to-energy plant captures and uses the landfill gas to produce electricity. The gas is extracted from the landfill site through a system of vertical wells, collectors and piping.

The extracted gas is then pretreated by a processing system which removes water and other impurities, leaving a gas that is rich in methane. The gas is combusted to produce heat energy, which is converted into electrical energy. The electricity is exported to Suzhou City local

power grid, part of the East China Power Grid.

Small-scale biogas production from biodegradable waste is a mature technology, and can be found in many parts of Asia.

Numerous designs of anaerobic digesters exist, but most are either the floating-dome or the fixed-dome design. The Deenbandhu model, for example, is a floating-drum hemispherical digester, while the Janata model is a fixed-dome plant with brick reinforced dome.

Not only is WtE a reliable means of reducing waste and producing renewable energy, it also has the advantage of re d u c i n g g re e n h o u s e g a s e s while providing energy security as par t of an overall waste management strategy. However, according to ISWA, almost 50 percent of municipal solid waste is landfilled in Europe on the average and many countries still rely predominantly on landfilling.

Therefore, the potential for waste to energy processes has yet to be fulfilled.

ENQUIRY NO. 7701 Oct/Nov 2010 | industrial automation asia 47

features

The

Business Of

In the face of environmental, social and governance challenges, CEOs in Asia are increasingly embracing sustainable practices in the playing field. By Teo Lay Lim, country MD; Ynse de Boer, senior manager, Sustainability Services, Accenture Singapore

C

EOs around the world are starting to see the shape of an era of sustainability coming into view. In the face of rising global competition, technological change and one of the most serious economic downturns in nearly a century, corporate commitment to the principles of sustainability remains strong throughout the world: 93 percent of CEOs see sustainability as important to their company’s future success.

There has been a fundamental shift since the last Global Compact survey in 2007. Then, sustainability was just emerging on the periphery of business issues, an 48  industrial automation asia | Oct/Nov 2010

increasing concern that was beginning to reshape the rules of competition. Three years later, sustainability is top of mind for CEOs around the world.

Although environmental, social and governance challenges continue to grow and CEOs wrestle with competing strategic priorities, sustainable business practices and products are opening up new markets and sources of demand; driving new business models and sources of innovation; changing industry cost structures; and beginning to permeate the business from corporate strategy to all elements of operations.

Alessandro Paiva, Brazil

Going Green

Public Faith However, business leaders in Asia Pacific appear to have greater confidence that they are trusted by the public and other stakeholders. For example, while 79 percent of CEOs globally believe that their company is trusted, 91 percent of APAC CEOs believe this to be the case. And, while 73 percent of global CEOs believe that their industry is trusted, 77 percent of APAC executives believe this to be true.

APAC executives appear to believe that their sustainability activities are contributing to this enhanced sense of trust. For example, Sung-joo Kim, CEO of South Korean retailer the Sungjoo Group, noted that: “Through our focus on sustainability, we earned trust and loyalty from our consumers; it became much better than those who [only] invested in advertising.

We cared for society and we showed how much we care, and eventually it led to far better recognition.”

It is generally true that Asia Pacific companies often enjoy higher levels of trust from consumers than their counterparts in the US and Europe. It is not yet clear, however, to what extent business leaders view their own role in rebuilding a more trusted position for business in society – and to what extent they feel that individual action can address a global environment that threatens business’ social contract, and sees some stakeholders ask serious questions about the purpose of business.

Driving Motivation A message that comes through from APAC executives is that the imperative to act on sustainability has shifted from a moral to a business case. In some respects, the economic downturn has been a prime cause of this move to drive sustainability initiatives based on business goals.

During a time of economic hardship, businesses have been forced to examine closely how their sustainability activity delivers core business value, measured in terms such as cost reduction and revenue growth. Among APAC CEOs, 80 percent believe that the downturn has led their company to align sustainability more closely with16:33 their Uhr core SG-729-CFFireWire 85x114 30.04.2008

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ENQUIRY NO. 180

Asian Perspectives More APAC CEOs than in any other region of the world (98 percent) see sustainability as either important or very important to their company’s future success.

In fact, 57 percent of APAC executives perceive sustainability issues to be ‘very important’ to their future success, a slightly higher proportion than the global average of 54 percent.

In the words of Hirokazu Hashimoto, president and director of the Japanese technology company Anritsu Corporation: “Sustainability issues are critically important for our company’s future.”

According to Zhongshu Zhou, president of China Minmetals corporation, “Sustainable development is a basic guarantee for our company’s survival and development.”

Although many factors contribute to this strong APAC support of sustainability, one important element is what one business leader termed the ‘lens of proximity’ of sustainability issues. That is, corporations and the public alike in emerging economies see sustainability in personal, local and immediate terms – eg: access to clean water, more direct dependence on the natural environment – and therefore perceive their future success to be more directly threatened by environmental degradation. For example, APAC CEOs emphasise more than their global counterparts the importance of access to clean water and sanitation, as well as achieving food security and alleviating hunger, as key sustainability issues.

Many CEOs are concerned about the damaged reputation of business in the wake of the recent financial crisis and economic downturn, and these business leaders appreciate the scale of the challenge in reestablishing confidence in the corporate community.

According to PM Telang, MD of Tata Motors: “The concept of ‘trusteeship’ is vital, both as a management philosophy and as a principle of governance.”

Oct/Nov 2010 | industrial automation asia 49

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business – a number exceeding the global percentage of 73 percent.

These regional CEOs are also more likely to see solid business returns from sustainability as a key driver. For example, 57 percent of APAC CEOs cite ‘cost reduction and efficiency’ from sustainability as an important opportunity over the next five years, compared with only 46 percent globally.

As one business leader pointed out: “If managing a business sustainably is about using resources efficiently, then it serves the cost agenda as well.”

APAC executives are especially focused on consumers as a key value driver – buyers who will create a viable marketplace for sustainable products and services. One finding of the research is that 66 percent of APAC executives named ‘consumers’ as a stakeholder group having the greatest impact on sustainability initiatives, compared to 58 percent globally.

It is likely that the emphasis on consumer demand expressed by APAC CEOs reflects the fact that most of these companies are global in nature.

So executives see consumer demand in terms of the global customer, not only the local one. As Carlos Ghosn, CEO of the Renault-Nissan Alliance, said: “We want to make the most eco-friendly choice a good economic solution for consumers as well.” Or, as Sung-joo Kim of the Sungjoo Group put it, “Sustainability started as a moral obligation, but has now become a key differentiator for consumers.”

Turning To Alternatives Executives are cautiously hopeful that they can see significant new sources of growth in ‘green’ products and services: As growth slows in traditional markets, companies are turning their attention toward new propositions that tap into new waves of demand. For

50 industrial automation asia | Oct/Nov 2010

APAC CEOs emphasise more than their global counterparts the importance of access to clean water and sanitation

example, Nissan is investing in a portfolio of green products, including clean diesels, efficient internal combustion engines and hybrids.

The centre-piece of its product strategy is the zeroemission vehicle. Nissan has successfully entered this market with the LEAF, a car that produces no carbon-dioxide emissions, uses advanced aerodynamic technologies and has a driving range of 100 miles on a single charge of its electric motor. The LEAF had 13,000 pre-orders in just over one month in the US and Japan alone, with more than 56,000 orders globally.

The survey found belief in an era of sustainable business – one in which sustainability is more than an aspiration or a separate initiative, but something

While sustainability has become part and parcel of how many businesses operate, it has yet to permeate the organisation into all elements of core business – that is, into capabilities, processes and systems.

fully integrated into the strategy and operations of a company. According to one of the CEOs: “Currently, the issue is how to better incorporate sustainability into daily practice.”

The past three years represent a significant mindset shift in how UN Global Compact CEOs think about the role of sustainability in strategy and operations. It was found that 96 percent of CEOs in APAC – identical to the global figure – compared to just 72 percent globally in 2007, now believe that environmental, social and governance issues should be fully integrated into the strategy and operations of a company. CEOs are also confident about the progress that they have made toward this era of sustainability.

For example, the most significant performance gap lies in the integration of sustainability issues into supply chains. Although 82 percent of APAC executives believe that they should be integrating sustainability throughout their supply chain, just 53 percent believe that this has been achieved within their company.

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ENQUIRY NO. 181

Ben Earwicker, USA

Business Of Assimilation The second most significant performance gap appears in the integration of sustainability issues into the strategy and operations of subsidiaries.

While there is widespread acceptance of the need to embed these issues into subsidiaries (88 percent in APAC) just 62 percent of APAC executives believe that they currently meet this ambition.

Given the opportunities and challenges that sustainability presents to Asia Pacific businesses, it has been observed that, while sustainability has become part and parcel of how many businesses operate, it has yet to permeate the organisation into all elements of core business – that is, into capabilities, processes and systems.

In particular, the difficulty of implementation, especially across supply chains and subsidiaries, is a significant barrier to the full integration of sustainability.

Although the outline of another era of integrated SG-741-E2-000 85x114 30.04.2008 16:36 Uhr Seite or embedded sustainability is becoming clear, the

Oct/Nov 2010 | industrial automation asia 51

1

Tata Steel company provides electricity, fuel, drinking water, and cooking gas free of charge to a community in West Bokaro, India.

means to get there and the timing of the journey are uncertain. Multiple stakeholders across industries and national boundaries will need to work in concert.

What are the conditions most important to enabling that tipping point to be reached? Among CEOs in the Asia Pacific region, the top two answers were related to education and government: educational systems that produce effective talent, as well as government action that provides clear support for sustainability.

APAC companies are highly committed to training their manager-level employees as a means of embedding sustainability objectives into operations.

There are 69 percent of APAC CEOs who state that they are already engaging in the additional training of managers to enable them to address sustainability issues. For example, Fuji Xerox is working to improve the skill sets of its workforce in the area of sustainability. It is educating its employees on sustainability issues, and on more effective management from an environmental standpoint.

It has created a specific environmental education program for all its employees, with tailored courses for particular divisions and job functions.

Authoritative Action Among business leaders in APAC, 88 percent believe that clearer direction from governments will be a critical impetus toward reaching a tipping point on embedded sustainability. These executives also express a greater belief than their global peers that they must proactively engage with policy makers, and demonstrate public support for global integration and open markets.

It was also found among APAC executives that a 52 industrial automation asia | Oct/Nov 2010

Mike Canon, Austria

features

commitment to partnering with local communities exists. In the words of Jamshed J Irani, director of Tata Steel: “Corporate social responsibility is an investment. Long-term community investment and partnership has contributed to operational viability and stability in challenging environments.”

Tata Steel sought to create a stable environment for business in West Bokaro, India, investing in local community infrastructure to support the scale of operations. West Bokaro Mines, first established in 1948, now contributes approximately 4.5 million tonnes annually to Tata Steel’s production capacity.

To sustain this level of production the company requires advanced support services for engineering and heavy equipment like dumpers and excavators.

Since the area in which the mine is located is underdeveloped, the company has to be self sufficient in many of its activities.

Tata Steel provides housing and accommodation for the population of about 3,700. The company provides electricity, fuel, drinking water, and cooking gas free of charge. The company also provides education for its employees’ children by constructing the infrastructure for schools and working with agencies to run them.

It was observed that there is a sense of optimism among many of the CEOs pertaining to operating in the area of broader social responsibility. In a number of ways, businesses should be able to couple both business value and societal value.

In doing so, businesses will be better able to reassert a stronger, more positive and influential role in society.

ENQUIRY NO. 7801

features

E

thernet is used in industrial and office IT environments around the world, providing effective communications that are easily installed and maintained.

The increase in the adoption of industrial protocols such as EtherNet/IP and EtherCat reveals a trend towards using Ethernet for industrial automation. However, machine vision applications such a s a l ig n me nt, gau g i n g a nd inspection require high bandwidth for raw image/video acquisition.

For example, a standard VGA resolution colour image with a 30 frame/second acquisition rate requires about 210 Mbps a nd e xce e ds t he ma x imu m usable ba ndw idth ava ilable from Ethernet.

The arrival of Gigabit Ethernet eliminates this weakness, and a camera that rides on it can transfer data using existing Ethernet technology. This allows users to leverage the technology for industrial vision applications and to take advantage of its capabilities – such as 100 metre long distance transmission and 1. 0 G b p s h i g h b a n d w i d t h .

Additional enhancements over traditional Ethernet make Gigabit Ethernet more effective for machine vision applications.

Need For Power Such cameras typically require a separate cable to provide power in addition to the data cable. The IEEE 802.3a Power over Ethernet (PoE) standard specifies how to deliver power over standard Ethernet cables and provides up to 48V of DC power to PoE-compliant devices over eight-wire Cat 5 and Cat 6 cables.

The voltage is nominally 48V and about 13W of power is available at the powered device. An isolated DC-DC converter transforms the 48V to a lower voltage as required by the electronics in the device, while maintaining 1,500V of

Industrial Ethernet:

Advances in technology are paving the way for more powerful machine vision applications. By Neil Chen, product manager for Vision Products, Adlink Technology isolation for safety reasons.

In order to provide a reliable solution, the inrush current limiter and short-circuit protector are also necessary in the electronic design – another requirement of the specification to prevent damage to existing Ethernet equipment. A ‘discovery process,’ executed from the power sourcing equipment, examines the Ethernet cables to look for devices that comply with the specification.

It does this by applying a small current-limited voltage to the cable and checks for the presence of a 25 kΩ resistor in the remote device. Only when the resistor is present is the full 48V applied.

But this is still current-limited to prevent damage to cables and equipment in fault conditions.

De sig ning, insta lling a nd maintaining wiring has always

been the major cost component in industrial vision systems.

Delivering power over the data or communication cables is a useful feature for the industrial vision market. With a single cable solution, industrial vision systems can provide simplified installation, lower maintenance, and reduced total cost of ownership.

Link Aggregation In the IT industry, link aggregation technology is used to combine multiple Ethernet links, or ports, to achieve higher data-transfer speeds than the current Gigabit Ethernet standard allows for a single link. Link aggregation offers an inexpensive way to set up a double-speed backbone network that transfers more data than a single port or device.

In high-speed machine vision Oct/Nov 2010 | industrial automation asia 53

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systems, doubling the current 1.0 Gbps data transfer rate would double frame rates or resolution, and provide higher speed image transfer or better image quality.

Standard Gigabit Ethernet uses a maximum 1,500 byte frame size.

‘Jumbo frames’ extend the frame size to 9,000 bytes, enhancing performance by allowing an image data packet of up to 9,000 bytes. This reduces the number of interruptions that are generated by incoming packets and also reduces CPU loading.

The enhanced features of Gigabit Ethernet make it attractive for machine vision solutions. Using robot systems as an example, robots have been used in factory automation for many years, including automotive, semiconductors, and flat panel displays. The benefits of using robots are numerous, including increased productivity; improved and consistent accuracy; and the reduction of costs.

The enhanced features of Gigabit Ethernet make it attractive for machine vision solutions.

and compact v ision system.

Among the major concerns on the components are computing power, bandwidth and cabling.

Both robot guida nce a nd inspection functions require image data and a power supply.

Having two cables means double the installation and maintenance wiring cost, and twice the chances of failure. The enhancement of the digital camera standard PoE, with the combination of the data line and power line into a single cable, is a common means for feeding the demand.

Machine vision applications such as alignment, gauging and inspection require high bandwidth for raw image/video acquisition.

The use of machine vision in robot systems has improved the accuracy of assembly. The vision function in the robot means automation and vision working together. It reduces the total cost by finding defects further downstream and increases the flexibility and the ability to assemble, gauge or identify, in production line at the same time.

Points Of Consideration The primary components of a robot system w ith a v ision inspection function include the robot, cameras, cables, lighting, 54 industrial automation asia | Oct/Nov 2010

With 3D robot guidance, there have been improvements in the accuracy and speed of assembly, picking and placing. The 3D calibration is the first key step of 3D vision. It establishes the relationship between robot, camera, and object coordinates, and then follows with the pattern match to locate the object – including the position and orientation. The robot trajectory is then determined based on the collected 3D data.

As these processes consume computing power and bandwidth, the jumbo fra me fe ature of Gigabit Ethernet can reduce the

frequency of interruptions and the host CPU loading. The link aggregation function can double the bandwidth for the image acquisition.

Importance Of Sight Vision inspection is needed for robot systems. Gigabit Ethernet, PoE, Jumbo frame, and Link aggregation technology offer greater flexibility in optimising the system configuration.

However t here a re some shortcomings that make it less suitable for certain machine vision applications. The extra packet overhead of the Gigabit Et her net protocol is one disadva nta ge, since G igabit Ethernet does not support Direct Memory Access (DMA) transfer.

Instead, it uses additional CPU resources for the transmission process and can affect the highperformance computing and time deterministic needs of certain machine vision applications.

Industrial automation products w i t h E t h e r n e t te c h n o l o g y h av e s u cc e s s f u l l y c r o s s e d the ‘chasm’ into early majority status, especially in machine v ision applications. Fur ther improvements should arrive in the future with technologies such as 10 GigE – a newer version of Gigabit Ethernet with a maximum data rate of 10 Gbps; and PoE+, which will provide up to 25.5 W of electrical power, along with data on Ethernet cabling.

ENQUIRY NO. 7802

The Perfect

Match Mutually compatible machine tool lubricants and proactive maintenance can help deliver the competitive edge in manufacturing.

By Peter Bird, European marketing advisor, ExxonMobil Lubricants and Specialties

I

n to d ay ’s i n c r e a s i n g l y comp et it ive env iron ment, especially for those small a nd me diu m - size d machine shops operating in the global manufacturing sector, ma x i m isi n g pro duc t iv it y is a must. Rising energ y costs, machine tool availability and just-in-time delivery all add to the mix of pressing issues facing maintenance professionals in this sector.

One of the most valuable things that any successful small to medium-sized manufacturing company can do is to incorporate a proactive maintenance approach as opposed to reactive maintenance.

A proactive philosophy regards

equipment maintenance as a strategic investment rather than a cost. Companies recognise that when they invest in protecting their assets, they can yield significant payback in terms of equipment durability and efficiency, as well as maximised performance and productivity.

Selecting The Right Machine Tool Lubricants W hether a ma nufacturing company specialises in producing nuts a nd bolts, complex gea r sets or high precision valves, keeping its equipment running efficiently is the key to profitability. Lubrication plays an integral role in reducing friction

between critical rotating and moving machine components.

This translates into equipment durability and availability.

For machine tools applications, the mixing of different lubricating oils and aqueous cutting fluids is unavoidable. As a result, compatibility is a key component to lubricant selection and helps to optimise equipment performance.

To he lp e n su re t hat t he machine tool runs smoothly, it is impor ta nt to choose a combination of high - qua lity lubricants – slideway oils, water soluble cutting oils, and neat cutting fluids – with the optimal compatibility.

Oct/Nov 2010 | industrial automation asia 55

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Slideway Oils Poorly formulated slideway oils may not separate readily from aqueous coolants. This results in the formation of ‘tramp oil’ which ca n comprom ise t he effectiveness of the coola nt by shortening its effective life and adversely altering cutting performance. Tramp oil can also lead to bacterial growth resulting in foul odour, short service life and potential employee health and safety concerns.

To identify a high-performance s l i d e w ay o i l , m a i n te n a n c e professionals should seek out products with the following performance characteristics: • Frictional Properties – this enables increased machine accu rac y a nd re duce s chatter and stick-slip • Coolant Separability – this enhances the performance and life of water based metal working fluids • Multifunctional – can be used in moderate hydraulic and gear oil applications within the machine tool Water Soluble Cutting Oils To optimise productivity, it is important to choose technologyleading aqueous coolants. The highest performing coola nts provide reduced maintenance requirements by re sisting biologica l attack, helping to extending batch life. Ease of ma intena nce needs to be balanced with good machine performance, and protection of machines and work pieces from corrosion and deposits.

In addition, the fluids should meet the latest health and safety reg ulations a nd be ea sy to monitor and maintain in service.

Collectively, these properties will help deliver long service life, 56 industrial automation asia | Oct/Nov 2010

To help ensure that the machine runs smoothly, it is important to choose a combination of highquality lubricants

excellent cutting performance a n d r e d u c e d m a i n te n a n c e downtime.

Neat Cutting Oils Neat or straight cutting oils are used in applications, which are beyond the typical performance profile of aqueous coolants, such as tapping and threading of high alloy steels. Properly formulated products can improve machining in high speed automated machining centres through outstanding cutting performance, reducing tool wear and enhancing surface finish.

Maintenance professionals should seek products that are: • Clear or light colour to a llow v isibilit y of t he workpiece • Low misting characteristics to help workplace safety and product usage • Chlorine free to support environmental concerns, while balancing with a high degree of lubricity and machining performance.

Check Your Oil The most essential and costeffective component of a successful

proactive maintenance strategy related to lubrication is the implementation of a comprehensive oil analysis program. Oil analysis is a series of tests that help determine the condition of internal parts and in-service lubricants. With this information, the useful lives of both equipment and oil can be extended by identifying early warning signs such as contamination and wear, which can minimise unscheduled maintenance.

For maintenance professionals who want to implement an effective oil analysis program that can save both time and money, the online Signum Oil Analysis Program can be considered. It offers users access and direct control of their lubricant sampling program. Users can manage all their oil analysis needs including: • Updating equipment registrations and select analysis options based on their equipment or maintenance needs • Track the status of samples at the laboratory • Direct actions based on a na lysis results a nd request sample kits

Streamline Inventory Management Another example of how small and medium-sized machine shop businesses can minimise costs is to adopt and maintain an efficient inventory management program.

There are several factors to be considered, the most important of which is recognising that inventory costs not only include the initial purchase price of materials but also the costs associated with handling and storage.

Typically, most machine shop managers do not want to utilise valuable space to store excess inventory. As such, a good best practice to follow is to work closely with suppliers to develop an effective cycle fulfillment process.

Lubricants take up a significant amount of storage area, but often the number of products can be

consolidated to a lower number of high-performance lubricants.

Multi-application low ma i nte na nce cut t i n g f lu id s operating together with compatible multi-functional slideway and other machine tool oils can help enable companies to reduce inventory and administration costs.

I n to d a y ’s i n c r e a s i n g l y competitive environment, maximising productivity is a must, especially for small and medium-sized machine shop businesses. Without equipment running efficiently, a company’s productivity and bottom line can be severely impacted.

By following the suggestions provided above, businesses can help enhance overall efficiency, lower inventory management costs and most importantly, maximise productivity.

ENQUIRY NO. 7803

ENQUIRY NO. 179

• Share critical results with colleagues in a secure, pa ssword protected environment

Oct/Nov 2010 | industrial automation asia 57

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Optimising

Ethernet Performance

in Manufacturing Plants

The consideration of environmental risks and the selection of suitable hardware are essential to long-term network performance and reliability. By Bill Wotruba, director, Networking and Connectivity Products, Belden

I

ndustrial Ethernet is trending to be the principal infrastructure choice for plant floor networks, just as Ethernet ha s long been the sta nda rd communications protocol in business offices. Both are built on the same standards-based networking platform (Ethernet LAN standard IEEE 802.3). The key advantage of industrial Ethernet is that it allows manufacturers to deploy a single platform to enable interoperability in connecting plant operations to corporate and administrative offices, and the Internet.

58  industrial automation asia | Oct/Nov 2010

This convergence of open, sta nda rds-ba sed Ethernet communications between plant and office levels of an enterprise generates advantages for both, including: - Ubiquitous access to real-time data to improve plant operations - Real-time collaboration, inventory visibility and production planning - Shop floor system integration with ERP for scheduling, planning, quality tracking and delivery information

- Reduced Total Cost of Ownership (TCO) due to faster installation, less costly maintenance and upgrades Understanding The Environment There is a major difference between insta lling Ethernet in an office environment where cables, hardware and connectivity components are sheltered and protected, and installing them on the ma nufacturing floor.

In industria l site s, network components may be exposed to temperature extremes, UV

ENQUIRY NO. 166

features

The indirect costs of Ethernet system failure may include lost productivity, delayed processes, cost of system shut-down and start-up.

Piotr Ciuchta, UK

radiation (sunlight), moisture, oil, chemicals and other contaminants – all of which can degrade the components’ physical integrity and electrical performance, resulting in intermittent outages or even total system shutdown.

Normal plant activities may also pose risks to network components.

For example, there may be constant machine movement and vibration, robotic machinery generating power spike s that incre a se Electromagnetic Interference ( E M I )/ R adio Fre quenc y Interference (RFI), forklifts and ot her me cha n ise d veh icle s traversing the work floor. These can damage sensitive electronics − and even the best Commercial OffThe-Shelf (COTS) Ethernet systems are not made to withstand such harsh and hazardous conditions.

The following guidelines are offered to help manufacturers ensure that the pla nt f loor communications infrastructure is built tough enough to withstand these challenges.

• Consider The Real Cost Of Downtime Manufacturers rely on automation, instrumentation and 60 industrial automation asia | Oct/Nov 2010

control data communications to relay sig na ls b et we en machinery, devices and control systems that activate events on an exacting and pre-determined schedule, with little or no margin for error.

Network administrators also require optimal security and manageability so that network availability attains 99.999 percent uptime or better. Yet analysts report that a large percentage of unplanned downtime in industrial operations is caused by network infrastructure problems. According to one such report, fully 72 percent of network faults can be attributed to failure at the Open Systems Interconnection (OSI) Layer 1 (Physical Media), Layer 2 (Data Link) and/or Layer 3 (Network).

Physical deterioration or electrical failure in critical data transmission components can lead to unreliable network performance and safety issues, and may lead to the loss of critical data, system downtime or even catastrophic failure. No matter what the industry, if a switch, connector or cabling

system fails, the cost of parts replacement a nd repa ir represents only a tiny fraction of the overall costs associated with production downtime.

The indirect costs of Ethernet system failure may include lost productivity, delayed processes, cost of system shut-down and start-up, possible lapses in security and safety, and the loss of service to customers relying on the plant’s output. These can send total downtime costs soaring to several hundred thousand, or even millions of dollars.

For example, an automotive assembly plant that is capable of producing one vehicle per minute would stand to lose profits of about US$2000 to US$3000 per minute for small car production, and up to US$8000/min for SUV and pick-up truck production.

• Specify Industrial Grade Components In specifying Ethernet physical media, data links and network hardware for plant floor installation, it is important to select hardened, industrial-grade components offering rugged construction and durability to provide optimal

performance over long service life. High quality industrial-grade Ethernet products should provide a lifespan similar to that of other automation system components – typically 10 to 30 years, which is significantly more than COTS products can deliver.

Other factors to consider include: conformity with the Et he r ne t L A N . I E E E 8 02 . 3 standard; Mean Time Between Failure analysis; mounting options such as DIN rail mounted, rack- or panel-mounted, or devices that bolt securely onto machines; and a small form factor to occupy less space and allow greater density within the limited space of control panels.

• Physical Media Options – Cables & Connectivity For the physical media layer, there are a host of industrialgrade products that conform to the Ethernet L A N.IEEE 802.3 standard, while resisting the effects of sunlight, volatile temperatures, moisture and chemicals.

Industrial cables will operate effectively in a wider temperature range (-40 o C to +85 o C) than commercial cables (0oC to +60oC).

Selection will depend on each plant’s network configuration and application requirements.

Industrial Ethernet cables/ connectivity include: - Heavy-duty, all dielectric, indoor/outdoor-rated optical fibre cabling in single-mode and multimode constructions.

Many feature water-blocking agents for added protection in moisture-laden environments.

- Industrial grade Cat 5e and Cat 6 cables with heav yduty oil- and UV-resistant jacke t s. S ome C ate gor y cables feature a bonded-pair inner construction in which

Normal plant activities may pose risks to network components, eg: constant machine movement and vibration, and robotic machinery generating power spikes that increase EMI/RFI

the conductor insulation of the pairs is affixed along their longitudinal axis to ensure consistent conductor concentricity and to prevent performance-robbing gaps between the conductor pairs during installation and use.

- C o nt i nu ou s f le x c a ble s desig ned for use w ith continuous motion machines and automation systems.

- Upjacketed and armored cables for extreme environments.

- Cables designed for use w it h le ad i n g i ndu st r ia l

- Low Smoke Zero Halogen (LSZH) cables, waterblocked and burial cables.

Oct/Nov 2010 | industrial automation asia 61

features

The key advantage of industrial Ethernet is that it allows manufacturers to deploy a single platform to enable interoperability in connecting plant operations to corporate and administrative offices, and the Internet.

come in a variety of copper/ fibre port configurations, port densities, industry approvals and mounting options.

- Firewa lls to secure a nd isolate a network while still permitting authorised data communications to pa ss through. Firewalls with Virtual Private Network (VPN) capabilities also allow secure, encrypted communication f rom a remote locat ion through the Internet.

- Wireless access points, clients and bridges in either DIN rail mount or IP67 enclosure-less housings now also support the faster, more secure and noiseimmune 802.11n standard.

Anders Engelbøl, Denmark

automation networking and communications protocols, such as EtherNet/IP (ODVA), Modbus TCP/IP, ProfiNet and Fieldbus HSE. - Industrial-grade connectivity components, such as: IP67- or IP20-rated UTP or STP patch cords, connectors, modular jacks and plug kits, adaptors, faceplates and surface mount boxes.

- Industrial-grade Cat 5e RJ45 and Micro (M12) cordsets and patch cords, including high flex versions.

• Switches & Hardware Options Similarly, at the information, control and device layers, a range of options is available. There are products to support both copper and optical fibre media, and switches capable of data speeds as high as 10 Gigabits 62 industrial automation asia | Oct/Nov 2010

per second. At a minimum, all of these components – switches, connectors, and other hardware – should offer robust construction and resistance to high temperatures, vibration and EMI. Typical COTS hardware is designed to operate from 0oC to +40°C, while industrial-grade Ethernet hardware operates efficiently from 0oC to +60oC – extendable to -40 oC to +85oC. Also, excessive moisture and corrosive chemicals can inflict serious damage to the electronics i n co m m e rc ia l s w itc he s, whereas ruggedised industrial switches can be securely sealed to prevent ingress of these substances (Conformal coating is also available for humid/moist applications).

Industrial Ethernet hardware components include: - Ha rdened ma na ged a nd unmanaged switches which

- Related accessories, such as hardened power supplies, SFP fibre transceivers and even software that provides network status, alerts and control from the automation network’s software or PLC. • Plan Ahead For Bandwidth & Redundancy With an ever-increasing number of Ethernet-cabled devices being added in today’s automation and control networks, it is an industry best practice to allow for sufficient bandwidth to handle current needs – with additional headroom to accommodate future expansion.

This is far less costly and labourintensive than having to upgrade incrementally over time.

One factor often overlooked when it comes to maximising network uptime and performance is redundancy. This is also considered an industry best practice, especially in missioncritical applications. Two kinds of redundancy are key to maintaining uninterrupted signal transmission and maximum uptime.

The first is power source redundancy. Specifying switches that have dual power input capabilities means that if one power source fails, the other immediately takes over.

The second is data path redundancy. The daisy-chain network topologies used by many industrial plants to connect automated machinery and devices have one inherent flaw – if any link between two switches fails, the entire system could potentially go down, as the devices on one network segment can no longer

communicate with devices in other segments. The solution is to ensure a built-in redundant data path into the network topology.

• Design For End-To-End Integration Another trend that is gaining traction across the industrial sector is specifying network infrastructure components from a supplier that is capable of providing end-to-end, fieldproven Ethernet solutions – tailored specifically to end user applications and environments.

A s ma ny compa nies have discovered, taking a ‘total system’ approach can be more cost-effective over the long run in terms of ease of maintenance, troubleshooting and upgrades.

And, an integrated system typically results in greater reliability in delivering optimal transmission performance – as well as increased peace of mind for those responsible for optimising network performance, day in and day out.

ENQUIRY NO. 7804

Baked Goods Manufacturer Relies On Rugged Industrial Switches One example of how redundancy provides value is a multinational, US-based food company manufacturing baked products in its Midwest facility. The firm upgraded its Ethernet system for plant automation and control with the goal of enabling realtime information flow across the plant and the enterprise.

In selecting Ethernet system switches, reliability and redundancy were of paramount importance. If any piece of equipment in the plant’s production process were to fail, it would be simply too costly to stop the production line and consequently, any excess product generated would have to be scrapped until the equipment could be repaired.

During the upgrade, the company installed 12 Hirschmann industrial grade Ethernet switches to route copper cables out to the equipment floor and HMI terminals. The OpenRail and MICE switches were selected because of their rugged construction and redundant ring topology.

Data path redundancy means that if a switch or media segment were to fail, the ring topology would kick in and reconnect the ring in the opposite direction. This is so that the remaining switches would continue to communicate with each other.

In addition, the switches contain a USB port for backing up and restoring the original configuration using an auto-configurator or USB drive. This means damaged equipment can be replaced, and a new switch quickly and automatically configured by inserting

the auto-configuration adapter. From this manufacturer’s point of view, the investment made in industrial strength switches can save hours of costly downtime that translates into several thousand dollars of saved revenue.

Oct/Nov 2010 | industrial automation asia 63

EVENT Preview

Rapid urbanisation and economic growth have resulted in increasing demand for energy. Asia Pacific’s energy demand growth of 2.4 percent per annum outpaces the world average of 1.5 percent. By 2030, an estimated US$7-9.7 trillion worth of investments are needed to meet the growing demand for energy in the region.

Shifting Landscapes In an age where climate change t h r e a te n s t h e s u r v i v a l o f generations, attitudes are shifting and the region recognises that it needs to move towards a sustainable energy paradigm. As such, the Asia Pacific region is collectively playing a critical role in shaping a viable global solution.

In particular, there is an impetus for the development of clean energy. Despite the global recession in 2009, clean and renewable energy investments in the region rose 25 percent to US$37.3 billion. Beyond investments for power generation, many countries in the region also need investments to further their energy efficiency.

Acco rd i n g to t he A sia n Development Bank (ADB), India will require US$3.16 billion for energy efficiency in the industrial and commercial sectors; the Philippines will require US$2.81 billion for energy efficiency and conservation programs; and for Thailand projects a minimum of US$698 million will be needed for the industrial and commercial sectors.

More often than not, companies perceive energy efficiency projects as involving high upfront costs, even though most energy efficiency investments are actually low risk projects with assured returns.

Furthermore, such projects face competition for internal funding from other kinds of capital projects that do not have the same risk reward structure. Significant energy savings could be achieved if the senior management of companies 64 industrial automation asia | Oct/Nov 2010

Singapore International Energy Week

adopt a lifecycle approach to improving energy efficiency within their organisations.

Businesses can benefit from cost savings, rising productivity and improved competitiveness when they incorporate energy e f f icie nc y improveme nt s in the overall value chain, from design, production to delivery.

Opportunities exist for businesses that are interested in moving the energy agenda from discussion to action in Singapore.

Fuelling The Smart Energy Economy The annual Singapore International Energy Week (SIEW) provides a platform for businesses to learn more about the role that they play

in impacting the energy agenda.

This is through ensuring the availability of clean, economically competitive and reliable energy supplies for sustainable business growth. Business leaders can come together with policy makers and academics to exchange ideas, strategies and share best practices to reach the investment goals that will need to be met by 2030.

This year, the event will feature a week-long schedule of energyfocused conferences, exhibitions and networking sessions with a diverse cross-section of energy industry leaders. Highlights during the week include the Singapore Energy Lecture, delivered by Singapore’s prime minister Lee Hsien Loong, and the Singapore

efficiency a nd susta inable development in Asia Pacific.

• PowerGEN Asia, an annual platform that targets the power generation, transmission and distribution industries to discuss strategic and technical topics and issues of the day.

Energ y Summit, comprising ministerial and senior executive dialogue on the transition to smart energy economies.

Speakers at the summit will include Abdullah Bin Hamad AlAttiyah, Qatar’s deputy premier and minister of Energy and Industry; Nobuo Tanaka, executive director of the International Energy Agency; Michael Dolan, senior VP of Exxon Mobil Corp; Tsunehisa Katsumata, chairman of the Tokyo Electric Power Company; and Dr Daniel Yergin, IHS Cambridge Energy Research Association’s founder and chairman. A number of energy ministers have also confirmed their attendance at the summit including Saudi Arabia, Malaysia, New Zealand and the Philippines.

SIEW will a lso feature conferences and exhibitions from partner organisations including PennWell and Koelnmesse. These include: • Carbon Forum Asia, which prov ides ca rbon ma rket professionals and governments with a platform to discuss key industry trends and issues that will shape the future of carbon trading and CDM markets in the Asia Pacific and beyond.

• Clean Energy Expo Asia, that will bring together the players in the technology, services, finance and government sectors, to address key issues in the areas of renewable energy, energy

Networking opportunities will be a significant draw for those businesses interested in making co n ne c t io n s w it h i ndu s t r y experts throughout the week.

These include three networking receptions hosted by the Energy Market Authority as well as the Bloomberg New Energy Finance Dinner and Platts Annual Top 250 Global Energy Companies Asia Awards Dinner. This year, business matching will also be available for attendees who are interested in setting up one-on-one meetings with particular businesses or partner organisations.

Nearly 12,000 participants are expected to attend events taking place from October 27 to November 4. Multiple exhibitors will cover several square metres at Suntec Convention Centre, Raffles City Convention Centre and Marina Bay Sands. These include country pavilions from over 20 countries including Australia, China, India, Japan, Brazil, the US, Demark, France and Spain.

Carbon Forum Asia expects some 150 international companies and organisations and Clean Energy Expo Asia is expecting a 50 percent increase in exhibition space and an increase of 20 percent in the number of exhibitors represented across the three-day event compared to 2009.

October 27 - November 4, 2010 Suntec Singapore ENQUIRY NO. 7901 Oct/Nov 2010 | industrial automation asia 65

EVENT review

PS Asia 2010, HVAC & Refrigeration Asia

The 10th edition of PS Asia 2010, the internationa l ex hibition on fluid, air and gas handling systems in Asia and the 8th HVAC and Refrigeration Asia 2010 - an exhibition on heating, ventilation, air-conditioning, air-filtration and purifications and refrigeration was held from September 1 - 3, 2010. The opening ceremony was attended Dra Masnellyarti Hilman, deputy minister of Nature Conservation Enhancement and Environmental Degradation Control, Ministry of Environment Indonesia.

The event was held at the Sands Expo and Convention Centre and featured over 170 exhibitors representing 29 countries. This event hosted a myriad of activities, with the interactive networking sessions from technical seminars, country industry forums, career opportunities talk to the high level process systems and HVAC conferences. Eg: Mitsubishi Electric was involved in a technical seminar for green technologies and ecoproducts in internal permanent magnet drives.

66 industrial automation asia | Oct/Nov 2010

The country industry forums offered infor mation on key market developments and policy movements in China, Indonesia, India, Korea and Philippines. The event attracted 5,326 visitors from 43 countries. Peter Klyver, marketing director of Östberg Group said: “The outcome from the exhibition is expected to contribute to our growth in the Singapore and Malaysia markets.”

V it tor io B o no m i , e x p or t area manager of Enolgas also commented: “We have met the right contacts at the show and have introduced and showcased products to the Asian market.”

Cheoh Kim Yam, MD of ACME Pump (Asia), said: “We are happy

to participate in PS Asia 2010 and will be back again in its next show in year 2012.”

“PS A sia 2010 has helped raise the awareness about ITT in energy efficient pumping systems with our introduction of our eSV pumps. Response from visitors about our solutions was good and we have generated several positive leads,” said Eddie Tan, GM Asia Pacific Residential & Commercial Water of ITT Fluid Technology Asia.

September 1-3, 2010 Sands Expo and Convention Centre Singapore ENQUIRY NO. 7902

EVENT Preview

OSEA

2010 The decline in available oil and gas resources in onshore areas has driven increased offshore exploration. This has resulted in discoveries of reserves in emerging regions. Asia Pacific is one of the regions that has become the focus of a shift in considerable investments.

This trend is expected to continue and is evident in the presence of technology and solutions providers at OSEA2010.

Drawing Crowds The event will be the largest edition in its 18-year history and will feature 1,500 international exhibitors over 24,000 square metres at Suntec Singapore. It is expected to see the participation of over 22,000 representatives from 60 countries and regions.

O S E A w il l b e held f rom November 30 – December 3, 2010.

It sees perennial participation by surface technologies companies such as Keppel FELS, Yantai Raffles Shipyard, J Ray McDermott Asia Pacific, Semco Maritime and Prosafe Offshore.

The increa se in subsea installation and production to exploit resources in deeper, less accessible waters in the region has driven demand for subsea technologies and services. Exhibitors include Technip Geoproduction, SapuraCrest Petroleum and Subsea7.

“The subsea industry is growing in importance, with many deepwater discoveries in the Asia Pacific region like Australia, China, India, Malaysia and the Philippines,” said

B T Tee, project director of OSEA at Singapore Exhibition Services (SES).

“There have also been deals and contracts concluded recently, for instance, the US$25 million subsea contract awarded to Hallin Marine – which indicates that companies will be looking out for more advanced subsea technologies and services.”

T he eve nt w il l fe atu re international group pavilions from Australia, China, Denmark, Finland, Italy, Netherlands, Norway, Singapore, US and UK. An international conference will be held concurrently with the exhibition and will feature an array of topics and panel discussions from the areas of exploration to production, gas technology and recovery.

The conference this year will see the debut of a leaders’ summit where industry representatives like John Westwood will be giving his forecast on the prospects for the global offshore industry, among other topics. Delegates can look forward to speakers from Abu Dhabi Marine Operating Company (ADMA-OPCO), Ebara, ExxonMobil, GL Global Denton, J Ray McDermott, and Kuwait Foreign Petroleum Exploration Company (KUFPEC).

November 30 – December 3, 2010 Suntec Singapore ENQUIRY NO. 7903 Oct/Nov 2010 | industrial automation asia 67

EVENT review

t he opp or tu nit y to pre sent in Interphex Centre sta ge, a technical forum for exhibitors to give presentations on their latest technologies and solutions.

The next edition of Interphex Asia will be held on May 30-31, 2011, Singapore.

Interphex Asia2010

In te r nationa l suppl iers, industr y reg ulators a nd professionals from both mu lt i nat iona l a nd re g iona l pharmaceutical manufacturers in the Asia Pacific region attended the event from June 7-8. The event was attended 1,211 visitors from 24 countries. It also showcased two official country pavilions – Ireland and Singapore.

68 industrial automation asia | Oct/Nov 2010

T he e ve nt at t rac te d 12 9 pharmaceutical manufacturing service providers and manufacturers from 19 countries including Germa ny, Irela nd, Malaysia, Singapore, UK and US. It showcased a variety of equipment, products and services relating to the pharmaceutical manufacturing processes.

Eight companies had

ISPE Singapore Conference 2010 With the theme of ‘Celebrating Grow th and Continuous Innovation’, the ISPE Singapore Conference was held from June 6-8 at Suntec Singapore. Four facility visits were also conducted on June 9, which was attended by more than 80 delegates.

Attended by 336 conference participants from the region, the conference programme consisted of t wo ha l f - day work shop s conducted on June 6, with a keynote plenary session and eight industry related breakout tracks being conducted over the remaining two days.

In partnership with Reed Exhibitions, the ISPE Singapore A f filiate orga nise d t he 10 t h anniversary of the affiliate and the conference on June 7 at Pan Pacific Hotel. Recognition for the long service award, most supportive company and tertiary institution was given during the dinner.

Additionally, the top five winners of the Student Poster Competition were announced.

Conference proceedings were distributed to the delegates by means of a CD and post conference presentations which are available for circulation were uploaded to the event website. The next edition of the conference will be held on May 29-31, 2011 in Singapore.

June 7 - 8, 2010 Suntec Singapore ENQUIRY NO. 7904

& Services productsproducts & Services

Belden:

Contec:

Belden has introduced a Layer 3 software that makes it possible to use all Gigabit Ethernet switches of the Hirschmann MACH1040 family as routers. Using wire-speed technology allows for fast functions, which includes static and dynamic routing, multicast routing (DVMRP, IGMPv1/v2/v3, PIM-DM) and router redundancy (VRRP, OSPFv2, RIPv1/v2).

The Hirschmann switches are designed specifically for use in the power industry. They can be connected to form sub-networks, which in turn can be linked to each other.

Contec has released its digitiser board with wave pattern judgment, the DIG100M1002-PCI. The digitiser board for PCI features simultaneous two-channel sampling with a maximum conversion speed of 100MS/s in 10-bit resolution. It automatically determines the pass/fail status of a substance.

It allows the use of a mouse to draw free-hand/straight line/ sine wave or constant voltage/square wave/chopping wave/ step/lamp/saw wave drawings via mathematical function and parameters. By using the application software ‘Front Panel’ a visual pattern is generated with the look and feel of an oscilloscope or a wave pattern emulation tool. This enables fast and easy implementation without programming.

Router Software

Digitiser Board

Enquiry no. 7905

Enquiry no. 7907

Carlo Gavazzi:

Fujitsu:

Carlo Gavazzi has launched the WM40-96, a smart modular power analyser. The device is used to measure the electrical variables – such as current, voltage, power, energy and harmonics – in applications where parameters analysis, control, data stamping and retransmission must be accurate.

With its streamlined modular basis unit and plug in modules, the analyser can be used in any application. The compact modular power analyser allows consumers to save space in the back of control doors and switchgears.

It features a keypad and a display that includes a single phase coloured bar-graph indication. A front optical communication port is also available, enabling quick access to measurements and easy programming.

Fujitsu Semiconductor has announced the development of a series in its F2MC-8FX family of high-performance 8-bit microcontrollers with embedded flash memory. The 32-pin MB95430H series includes six products with a built-in analog comparator and operational amplifier.

The products are targeted for use in home appliances and industrial equipment - such as induction cookers, power tools and auto-testers.

In addition to its primary function as main microcontroller unit, the series is also suitable as a sub-controller when current system configuration functions are insufficient – due to the availability of high current protection and various composite timer communication functions.

Smart Modular Power Analyser

Microcontrollers

Enquiry no. 7906

Enquiry no. 7908 Oct/Nov 2010 | industrial automation asia 69

products & Services

GE:

National Instruments:

GE Intelligent Platforms has announced another version of Proficy Plant Applications, providing improved global functionality and system performance, with more user interface options and conformance features. It facilitates manufacturing intelligence capabilities within the Proficy software platform and helps companies to improve operating performance and production execution.

The software automates and integrates the information activities in production execution and per formance management. These include managing and applying targets and limits for processing and quality parameters, logging actual data about processes and production events, as well as deriving relevant ‘intelligence’ from raw data for situation awareness in real-time.

National Instruments has announced N I DIAdem 2010, its latest version of the data management software that helps engineers and scientists to manage, analyse and report on data collected during data acquisition or generated through simulations. This version features GPS synchronisation, sound data playback and increased offline analysis and reporting capabilities.

This combination of features gives engineers and scientists the opportunity to increase the return on their data investment by reducing the time it takes to make decisions from data collected in applications – such as automotive, aviation and structural and environmental monitoring.

Manufacturing Intelligence Software

Data Management Software

Enquiry no. 7909

MDC Max Daetwyler:

Enquiry no. 7911

Silicon Software:

Water Jet Cutting Machine

Frame Grabber

MDC Max Daetwyler and Waterjet in collaboration with NUM, have introduced a CNC-based water jet cutting machine that is capable of cutting materials to within ±1 micron. The Womajet/MicroWaterjet consumes considerably less water and abrasives than traditional systems.

Using a jet of water to perform the cutting operation ensures that the material structure remains unchanged. The technique can be used on virtually any type of material – even foodstuffs, providing that they are not water soluble.

The machine can handle land widths as narrow as 20 microns (0.02 mm). It uses a high-precision water jet, with a diameter of less than 300 microns, and can cut materials at a rate of up to 4,000 mm per minute.

Silicon Software is in t r o ducing its PCIe x4 frame grabber. This grabber supports the Basler A406k /kc Camera Link camera at its full bandwidth. The microEnable IV series supports the maximum speeds via a PCIe x4 interface.

It reaches a transfer rate of 837 megabytes per second in a 10 tap, full configuration mode at the camera’s full 2320 x 1726 pixel resolution and a repetition rate of 209 frames per second.

Because the data is transmitted via a DMA channel into the host RAM, additional processing for image reconstruction is not necessary. The frame grabber is multi-board enabled and supports the use and synchronisation of multiple full configuration cameras in one system. The microEnable IV AD4-CL and VD4CL frame grabbers support both Windows and Linux operating systems in a 32-bit and a 64-bit mode respectively.

Enquiry no. 7910 70 industrial automation asia | Oct/Nov 2010

Enquiry no. 7912

Calendar of Events 9 - 12 Electronica 2010

October 12 –13 Pharma Manufacturing China 2010 InterContinental Hotel Shanghai, China Oppland Email: ajiang@opplandcorp.com Web: www.opplandcorp.com/pharma/

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

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

10 –13 Indo Aerospace Expo & Forum

25 – 28 CeMAT Asia

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

27 – November 4 Singapore International Energy Week

28 – 30 India Chem 2010

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

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

November 3 – 5 Autotek Indonesia 2010 Jakarta International Expo Jakarta, Indonesia FireWorks Indonesia Email: info@asiafireworks.com Web: www.autotekindo.com

New Munich Trade Fair Munich, Germany Messe München Email: info@electronica.de Web: www.electronica.de/en

9 – 13 CIIF

19 – 21 EP China 2010

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

2010-2011

JIExpo Kemayoran Jakarta Jakarta, Indonesia Napindo Media Ashatama Web: www.indoaerospace.com

30 – December 3 OSEA 2010

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

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

1 – 4 CIL Indonesia 16 – 19 Seoul Pack 2010 Kintex Seoul, South Korea Korea Packaging Machinery Association Email: seoulpack@seoulpack.org Web: www.seoulpack.org

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

Jakarta International Expo (JIExpo) Jakarta, Indonesia Allworld Exhibitions Email: info@oesallworld.com

January 19 – 21 Internepcon Japan

Tokyo Big Sight Tokyo, Japan Reed Exhibitions Japan Email: inw@reedexpo.co.jp Web: www.nepcon.jp/en/

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

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

23 – 26 Inatronics 2011 23 – 26 Indonesia Power

Grand Hyatt Jakarta, Indonesia IBC Email: register@ibcasia.com.sg Web: www.ibc-asia.com/indopower

24 – 27 Metalex Thailand 2010 BITEC Bangkok, Thailand

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

Reed Tradex Email: Channipar.Vala@reedtradex.co.th Web: www.metalex.co.th

The Editor IAA Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building, #04-02, Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 • Email: iaa@epl.com.sg

JIExpo Jakarta, Indonesia GEM Indonesia Email: info@inatronics-exhibition.net Web: www.inatronics-exhibition.net

28 – 31 Biologic Manufacturing World Asia Marina Bay Sands Singapore Terrapinn Email: paul.lim@terrapinn.com Web: www.terrapinn.com/2011/ biologicasia/

Advertising Index

64

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IndustrialAutomationAsia

ADVERTISING I N D E X

ADVERTISER

ADVERTISING SALES OFFICES

PAGE NO

ENQ NO

ABB Pte Ltd

9

173

HEAD OFFICE

Advantech Co Singapore Pte Ltd

23

169

SINGAPORE Eastern TRADE MEDIA PTE LTD 1100 Lower Delta Road #04-02 EPL Building Singapore 169206 Tel: 65-6379 2888 Fax: 65-6379 2805/6379 2806

Autotronic Enterprise Co. Ltd

27

183

Belden Singapore Pte Ltd

31

175

CEJN Products Far East Pte Ltd

43

171

Daifuku Mechatronics (Singapore) Pte Ltd

57

179

2&3

170

E-T-A Asia Pacific Pte Ltd

29

144

Exxon Mobil Asia Pacific

21

126

MEDIA REPRESENTATIVES

Fluke South East Asia Pte Ltd

39

172

Fuji Electric Asia Pacific Pte Ltd

7

161

Hitachi Asia Ltd

45

079

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

Emerson Process Management Asia Pacific Pte Ltd

Igus Singapore Pte Ltd

49/51

180/181

JJ-Lapp Cable (S) Pte Ltd

41

178

Messe Frankfurt (HK) Ltd

25

160

Misumi South East Asia Pte Ltd

5

177

Mitsubishi Electric Asia Pte Ltd

OBC

182

PT Fireworks Indonesia

33

167

Rockwell Automation Southeast Asia Pte Ltd

IFC

120

SICK Optic-Electronic Pte Ltd

1

168

Singapore Exhibition Services Pte Ltd

59

166

Singapore Oriental Motor Pte Ltd

IBC

174

VEGA Instruments (SEA) Pte Ltd

15

176

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