IAA September 2012

September 2012 IndustrialAutomationAsia

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September 2012

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

Water/Waste Water Treatment | Wireless Insight | Motion Sensors | Electric Vehicles

Flow Monitoring For Greater Control

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Integrating A

Wireless Plant

Sensing A

Way Forward

Zero Emission:

Brighter Future

DCS forthe thesize sizeand and priceofThe ofa aPLC? PLC? DCS for800xA price System High Integrity. gulf between Absolutely.

Absolutely.

SIL3 and safety leadership is bigger than you think.

DCS for the size and price of a PLC? Absolutely.

ABB’s Freelance process control system is gap? the perfect alternative a PLC - SCADA Does your SIL3 safety supplier close Why settle forto anato out-of-date ABB’s Freelance process control system isthat the perfect alternative PLC - SCADA safety system architecture?

Whether you want a segregated or fully integrated solution for small to medium applications.

With Freelance, you get the best of both solution for small to medium applications. With Freelance, you get the best of both solution, ABB’s innovative architecture you money throughout lifecycle of worlds: DCS functionality such asintegrated an integrated automation including ABB’s Freelance process control system is saves the perfect alternative to aenvironment PLC the - SCADA worlds: DCS functionality such as an automation environment including the system.

Regardless of applications. yourlibraries, needs, With our 800xA High Integrity solution provides solution for small to medium Freelance, you get the best of both single tag database, solution pre-integrated HMI, fieldbus management, single tag database, solution libraries, pre-integrated HMI, fieldbus management, andand worlds: DCS suchyour as at an integrated automation environment including features that functionality go diagnostics far beyond average safety system, reliable comprehensive the size price aproviding PLC. Tryboth our “Automation comprehensive diagnostics all atallthe size and and price of aof PLC. Try our “Automation single tag solution libraries, HMI, fieldbus management, safety anddatabase, business value like only apre-integrated leader can.

We technology have been atis the forefront Decision Tool” today to see which process control right forand you.of Decision Tool” today to see which process is right for you. comprehensive diagnostics all than at the size andcontrol price oftechnology a PLC. Try our “Automation safety automation for more 30 years.

For more information, visit For more information to: go to: www.abb.com/controlsystems For more information Decision Tool” todaygo to see www.abb.com/controlsystems which process control technology is right for you. www.abb.com/controlsystems.

For more information go to: www.abb.com/controlsystems

ENQUIRY NO. 486

ENQUIRY NO. 480

contents september 2012

ISSUES & INSIGHTS

26

Are You Sending People In Harm's Way?

30

Next Generation ISA100 Plant Wide Wireless Solution

Your most important asset is people. Therefore plants strive to reduce the amount of time personnel spend in harm's way. The amount of time operators work in the field can be minimised by automating manual tasks such as clipboard rounds for collecting data. Modernisation with WirelessHART enables new automation in existing plants with minimal risk.

By Jonas Berge, Emerson Process Management

Reliable, flexible, and open communication is of key importance to an effective communications infrastructure in today's industrial plants. ISA100.11a presents a step forward in industrial wireless for the industry. By Masaaki Matsuzaki, Yokogawa Electric

Process CONTROL

34

From PLC To PC-Based Control

Control Chief Corporation is a company, based in Pennsylvania, US, that provides solutions for controlling cranes and locomotives. The company explains why they decided upon PC-based control from Beckhoff Automation. By David Chia, Beckhoff Automation (Southeast Asia)

SOFTWARE & NETWORKS

36

Unified Physical Infrastructure Solutions For Industrial Automation

Optimising control panel layouts for noise mitigation in factory automation systems. By Dan McGrath, and Michael Berg, Panduit

Instrumentation & Measurement

42

Integrated Solutions For Motion Sensing In Handheld Devices

Implementing new gyroscope designs is taking shape and enabling more precise and cheaper solutions for motion control.

By Dr Farrokh Ayazi, Qualtré

44

Control Of Motorised Wheelchair

IAA spoke with LifeLine’s MD on their innovation in the motorised wheelchair market, turning teeth clenching into motorised movement. By Mark Johnston 2 industrial automation asia | September 2012

My people are forced to waste their time on monotonous procedural tasks.

I need them focused on right-first-time production instead.

YOU CAN DO THAT Empower your people and accelerate your business with the Syncade™ Suite.

ENQUIRY NO. 404

By simplifying routine, non-value-added tasks, Syncade helps your people be more effective and your plant be more efficient. You can integrate work activities with real-time information, assuring consistent production is performed with best practices and approved, up-to-date procedures. And the modular, scalable nature of Syncade let’s you add functionality as you need it. It’s time to put the focus back where it belongs – on your business – scan the code below or go to EmersonProcess.com/Syncade

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

contents september 2012

ENERGY

54

46

In the face of acute shortages in the near future, decision makers need to adopt reliable and sustainable technology to ensure uninterrupted access to water sources. By Lau Wee Pheng, and Sim Jee Kar, Mitsubishi Electric Asia

Fostering Innovation

IAA spoke with Oliver Kuttner, founder and CEO of Edison2, at Solid Edge University 2012. Edison2 broke all land speed records with his new generation of electric car, with high efficiency and speed never before reached by an electric vehicle. By Mark Johnston

The Rising Electric Vehicle

48

Interest in electric vehicles is gaining momentum around the world and most major car manufacturers are starting to produce electric cars. The increased interest and usage of Electric Vehicles (EV) would have to be supported by intelligent EV charging networks, and a local company, Greenlots, is set to lead in global EV charging solutions.

By Mark Johnston

The Quest For Clean Water

FEATURES

58

The Forklift Of The Future: Integrating Voice, And Barcoding Technologies Technology is playing an increasingly prominent role in the life of manufacturers, enabling more efficient processes and cost savings.

By Mike Muller, Intermec (Asia Pacific)

SECTOR SPOTLIGHT

EVENTS

50

60 61 64

ABB Service In Water

ABB makes provision of electrical Balance Of Plant (eBOP) service to world’s largest covered wastewater treatment plant. By Joseph Quek, service sales & marketing manager, ABB

OSEA 2012 Solid Edge University 2012 Honeywell HUG 2012

Regulars

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Fieldbus Foundation

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

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The modern world is the direct result of innovation and intellect, the process of innovation directly improves a manufacturers products, processes, services, and technologies, and ultimatly improves a company’s bottom line.

There is much innovation in engineering, and particularly in the field of automation where current trends see Ethernet technologies, virtualisation, advanced graphics, and mobility as areas to watch going forward.

When we think of modern innovations, we may think of the Internet, and social media products, such as Twitter and Facebook, at least for the younger generation. But it is important to know what is an innovation and what is merely an evolution, such as 3D TV, one would say the invention here is TV more than 100 years ago, not the fact it is now 3D, this can be considered merely a natural evolution of moving images, from black and white (B&W) silent movies to movies with sound, then colour TV, to HD TV, and now to 3D TV. If we look at manufacturing automation, for example, it is not seen as having the same level of innovation, but the impact of innovation in this field can still be felt by the industry.

In energy management and power we see innovations relating to drives, motors, power management, and power distribution applications. With today’s new and varied devices we can monitor and manage energy use, provide accurate forecasts for energy demand, track energy cost variations, and then schedule energy intensive processes to run during times when the energy cost is at its lowest.

Further innovations include more reliable Ethernet networking, more powerful microcontrollers enabling complex and distributed control, and advanced software for design and visualisation.

In this issue of IAA we focus on wireless solutions for plants, PC-based control, panel layouts for noise reduction, motion control solutions, electrical vehicles, and water/waste water treatment.

We also have event reviews for Solid Edge University 2012, and Honeywell’s HUG 2012, together with an event preview for OSEA 2012.

editor

Joson Ng josonng@epl.com.sg Assistant editor

Mark Johnston markjohnston@epl.com.sg Editorial Assistant

Audrey Ang audreyang@epl.com.sg Graphic Designer

Peh Loon Chin pehloonchin@epl.com.sg Senior Sales Manager

Derick Chia derickchia@epl.com.sg senior CIRCULATION EXECUTIVE

Brenda Tan brenda@epl.com.sg Contributors

Jonas Berge, Masaaki Matsuzaki, David Chia, Dan McGrath, Michael Berg, Farrokh Ayazi, Joseph Quek, Lau Wee Pheng, Sim Jee Kar, Mike Muller Editorial Consultants

Jim Pinto Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

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6 industrial automation asia | September 2012

ENQUIRY NO. 484

Fuji Electric Asia Pacific Pte Ltd

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Telephone: +65 65330010

Industry News

John Byer, Woodbridge, Suffolk, UK

Cummins Power Generation Announces Tier 4 Final Readiness Singapore: Cummins Power Generation’s entire stationary diesel generator set range from 680–2,750 kW, including its Mission Critical 2,500 kW diesel generator set, has received Environmental Protection Agency (EPA) Tier 4 interim (Tier 4i) certification for the North American market.

“I am delighted to announce that our Tier 4 interim certified generator sets are Tier 4 Final ready and fully capable of meeting the most exacting EPA requirements three years ahead of schedule. Our customers’ operational flexibility is further enhanced with a clear roadmap to meeting EPA Tier

4 Final requirements in 2015,” said Tony Satterthwaite, VP, Cummins and president, Power Generation Business.

EPA mandates that all nonemergency applications be Tier4i certified. Nonetheless, in certain locations, the local ordinances may require that emergency backup generators also adhere to stricter emissions limits. Because the company’s stationary diesel generator sets can be configured to meet requirements beyond Tier 4i if necessary, its generator sets are available to comply with the most stringent emissions regulations

TelStrat Signs Engage Suite Distribution Agreement With Ingram Micro Asia

Singapore: The largest European supplier of solar modules, Renewable Energy Corporation (REC), is one of five solar energy research teams selected to receive grants totaling �6.9 million (US$87 million) under the Clean Energy Research Program (CERP).

The CERP was launched by the Energy Innovation Program Office (EIPO) in 2007 to expedite the development of the clean energy industry in Singapore with key initiatives such as the establishment of public sector R&D centres, competitive funding and talent development programs. The fifth and final grant call from the CERP concentrated on two areas: improving silicon wafer-based solar cell manufacturing processes and technologies and thin-film solar cells based

8 industrial automation asia | September 2012

on the Chalcopyrite materials system.

REC received a grant for a proposal to develop and industrialise cost effective and high performing back contact modules based on back-contacted cells using high efficiency Metal Wrap Through (MWT) technology. In this project, the company will work closely with its partner ASM Technology Singapore.

T h e c o m p a n y ’s p ro p o s a l aims to both reduce module manufacturing costs and improve module e f f i c i e n c y. T h i s innovation allows manufacturers to stay cost competitive without compromising the quality and performance that customers expect.

John Nyberg, Copenhagen, Vanloese, Denmark

REC Awarded Funding From Clean Energy Research Program

Texas, US: TelStrat, a supplier of contact centre solutions and business call recording products, has signed a distribution agreement with Ingram Micro Asia. The agreement allows Ingram Micro channel partners in Singapore, The Philippines, and Vietnam to sell and distribute TelStrat's call recording and workforce optimisation solution portfolio, Engage Contact Center Suite.

The distribution agreement will particularly help Ingram Micro channel partners easily provide bundled call recording and WFO solutions with Cisco sales proposals, whether for smallmedium business, large enterprise, or cloud-based deployments. TelStrat will also work with Ingram Micro to promote VAR sales, supply pre-sale and post-sale technical support services, and provide solution training for Engage products.

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Industry News

Tianjin, China: Honeywell has opened a new office in the Huaming Industrial Zone of Tianjin, northern China.

A subsidiary of Honeywell Tianjin, the facility will provide engineering services and turnkey solutions – including design, systems integration, testing and training – for the company’s process industry customers in China and the Asia Pacific region.

Spanning 7,000 square meters and serving as the operational base for the company’s engineers, the office will serve customers in oil and gas, chemical, power and pulp and paper industries.

Innovation has been the driving force of the company’s continued growth worldwide, particularly in high-growth regions like China. In China, the company has established research, development, and engineering facilities in major cities like Beijing, Shanghai, Tianjin, Nanjing, Suzhou, Xi’an, with over 1,400 dedicated technologists and scientists tackling challenges including energy efficiency, energy generation, safety and security. Prior to the new

Honeywell has research, development, and engineering facilities in major cities throughout China, including Beijing.

Bobby McGill, San Franisco, California, US

Honeywell Opens Industrial Automation Engineering Facility In Tianjin, China

engineering facility in Tianjin, the company established a global engineering service facility in Chongqing in 2007, with a dedicated engineering team to solve local customer problems.

NXP, Infineon, Gemalto, And G&D Look Set To Prosper From Opportunities In China’s Smart Card Market London, UK: China has traditionally been a fairly closed loop market with only local vendors chosen to participate in the deployment of government issued credentials to its citizens. However, China’s desire to adopt higher-level microprocessor contactless technology has allowed the likes of Infineon and NXP to win new contracts ahead of the domestic competition.

China continues to be an integral part of the market, accounting for approximately 13 percent of all worldwide smart government ID shipments in 2011. It currently has the largest single national ID project with an installed base of over 900 million.

It is also migrating to e-passports and introducing new social security/payment

Like

cards, up to 800 million of which will be deployed by 2015.

Both Infineon and NXP have demonstrated that accessing the Chinese market is possible. As the Chinese government looks to make use of high-end technology, expanding the supplier base has become a necessity to fill the need for security and memory capacity.

Research analyst Phil Sealy, research analyst, ABI Research comments: “In the short to mid-term, NXP and Infineon will have success in the Chinese region with the deployment of e-passport ICs. They are both strong contenders to become suppliers for China’s new dual interface social security card with payment functionality. Gemalto and G&D are

also operational with the deployment of PBOC 2.0 payment cards, showing that China is certainly softening its approach towards international vendors.

It is important for companies looking at China to act now before local vendors develop a comparable solution.”

John Devlin, security & ID practice director, ABI Research adds: “The primary driver for bringing in international vendors is the desire to adopt the highest level technology; the leading IC suppliers believe China is three to four years away from developing a comparable solution.

It will be interesting to see if China’s adoption of the technology outweighs recent policy favoring local vendors, such as Eastcompeace, Tongfang Microelectronics, and CEC Huada.”

www.facebook.com/IAAsia

10 industrial automation asia | September 2012

Industry News

Agilent Technologies' Cary FT-IR Wins Industrial Design Award From Instrument Business Outlook California, US: The Cary 630 FTI R s p e c t ro m e t e r f ro m A g i l e n t Technologies has won the 2012 Instrument Business Outlook (IBO) Industrial Design Gold Award. Now in their 19th year, the awards highlight excellence in the industrial design of analytical instruments. The 2012 winners demonstrate how industrial design can improve a product's functionality and the user's experience.

The Cary 630 took a year and a

half to develop. Key to the system's design was its modularity, which allows for different uses and applications via each of the five interchangeable sample modules. Benchtop lab spectrometers have been shrinking in size for years, and this has one of the smallest lab footprints to date. The 3.8 kg (8 lb), 16 x 13 x 13 cm (6 x 12 x 5 in) system is designed for routine applications, with a spectral resolution of less than 2 cm-1.

To be eligible for one of this year's awards, a product must have begun shipping between August 2011 and July 2012. Candidates were chosen from the products that IBO monitors through trade shows, trade publications, press releases and the Internet. Winners were selected solely based on their industrial design, not on technical capabilities or performance. Judges considered innovation, aesthetics, functionality and features.

Tokyo, Japan: Hitachi Plant Technologies and Mayekawa Manufacturing have agreed to form a joint venture company providing maintenance services for industrial equipment in Brazil for the purposes of expanding their Oil & Gas (O&G) plant businesses. The contract was signed officially on August 9, 2012.

The contract, for which Hitachi Plant Technologies and Mayekawa Manufacturing have been preparing since signing a memorandum in March of 2011, will establish a joint venture company to be used as a base for maintenance services for industrial equipment in O&G plants, including Compressors, Pumps, and Reverse Osmosis (RO) equipment (Seawater Desalination unit).

The joint venture company will be established in November 2012, under the name Hitachi-MyCom maintenance & Solutions (tentative title). Hitachi Plant Technologies will own 90 percent, and Mayekawa Manufacturing, 10 percent of the company. Company headquarters and maintenance facilities will be established at a plant operated in SĂŁo Paulo, Brazil by Mayekawa Group's local subsidiary, Mayekawa Do Brasil.

Recent discoveries of large O&G fields off the coast of Brazil are expected to spur investment in O&G plants there, including Floating Production, Storage and Offloading (FPSO) systems. With the increased demand for industrial O&G plant equipment comes increased demand from customers for improved and expanded support systems covering the entire product life cycle, including equipment maintenance.

This joint venture company is being established to

Mokra, Brazil

Hitachi Plant Technologies And Mayekawa Manufacturing To Form Joint Venture In Maintenance Services For Industrial Equipment In Brazil

SĂŁo Paulo, Brazil

meet these needs, creating a synergy of Mayekawa Manufacturing's resources, notably its Brazilian customer base, facilities and management expertise, with Hitachi Plant Technologies' product lineup, and expanding the company's O&G plant maintenance service structure while strengthening sales.

Specifically, this will involve combining the maintenance services of both companies to cover equipment such as Hitachi Plant Technologies' Centrifugal Compressors, Reciprocating Compressors, Injection Pumps and RO equipment, as well as Mayekawa Manufacturing's Screw Compressors and other equipment. Maintenance services will be provided for products from both companies, while actively working to pursue orders for maintenance of other companies' products and to acquire new business.

September 2012 | industrial automation asia  11

Industry News

Kuala Lumpur, Malaysia: Companies in Southeast Asia and Australia-New Zealand have responded tepidly to automation and controls solutions. Due to the economic downturn, they have deferred large-scale expansion plans but have not completely stalled R&D investments.

The impressive industrial growth has made these regions fertile markets for automation techniques.

Analysis from Frost & Sullivan, Automation and Controls Market in Southeast Asia and Australia-New Zealand, finds that the market earned revenues of US$921.4 million in 2011 and estimates this to reach US$1.88 billion in 2018.

Automation companies will be heartened by the market’s prospects but they, especially the majors, will also have to strategise for the stiff competition in the market. Currently, there is little specificity in technologies and in some cases, PLC and DCS can be used interchangeably. However, technologies such as PLC, SCADA, and DCS will continue to remain vital to industries and will be significant contributors to market revenue.

The market will also get a leg up from the developments in end-user industries. The higher demand for power and water across Southeast Asia and Australia will stoke the markets for solar and wind energy, which,

Laura Leavell, Longwood, Florida, US

Industrial Growth In Southeast Asia And Australia Bolster The Automation And Controls Market, Finds Frost & Sullivan

Industrial growth on the rise.

in turn, will require automation. The flourishing mining and oil and gas industries in Australia will provide an extra thrust to the demand for automation solutions.

Meanwhile, the rising green consciousness is encouraging the installation of smart grids and new generation technologies, all of which require automation to function optimally. Most countries generate demand for automation by investing in infrastructure, whereas Vietnam contributes through events and exhibitions.

Qualcomm Number One In Commercial Telematics Competitive Assessment London, UK: Qualcomm Enterprise Services (QES) has been named the leading commercial Telematics Service Provider (TSP) in the latest Competitive Assessment released

by ABI Research. The company’s global reach, dominant market share, and intuitive product range were all fundamental to securing the top spot.

Telogis, Trimble, Masternaut, and Xata complete the top five.

The ‘vendor matrix’ is a key component of this assessment that has been developed by ABI Research to provide a clear and unbiased understanding of vendors’ positions in specific markets. In the case of 12 industrial automation asia | September 2012

commercial telematics, TSPs were scored against 12 different criteria falling under the broader categories of ‘innovation’ and ‘implementation’.

Market share, which measures total global active subscribers, carries a 25 percent weighting in the implementation category and QES is easily the dominant player in what is an extremely fragmented market.

The company also ranks first in the implementation category as a whole (which, in addition to market share, examined pricing, vertical segments, regional coverage, hardware configurations, organisational health and quality, and reliability). Trimble

and Telogis placed second and third, respectively. For innovation, companies received scores for user interface, features, integrated navigation, vehicle monitoring sensors, and interfacing with converged devices. Xata secured the top spot, marginally ahead of Telogis and TomTom Business Solutions.

This competitive assessment provides a rating of the leading commercial vehicle telematics service providers. A total of 18 companies were scrutinised against several criteria under the categories of implementation and innovation in addition to a market share analysis for the same 18 companies.

Industry News

US PMI Stays Flat At 49.8 Indicating Continuing Manufacturing Issue For Handset Semiconductor Suppliers And Device Vendors London, UK: US PMI data for July 2012 stays flat at 49.8 from 49.7 in June 2012, this is indicative of a wider global malaise that is mirrored by not only other regional PMI index’s but also the results of major Semiconductor vendors.

Lack of manufacturing capacity for key components coupled with the lack of investment in new fab space mean that this problem is likely to continue for a number of months and will eventually limit the availability of key flagship mobile products. This has been a major issue for Qualcomm; due to lack of availability of its S4 smartphone platform solutions it has been unable to satisfy customer demand.

“There is a lack of semiconductor manufacturing capacity, as highlighted

by Qualcomm’s recent troubles” said Peter Cooney, practice director, semiconductors, “There is a general industry sentiment that there is a lack of predictability in orders with many last minute orders being made rather than definite long-term future order planning; therefore, internal and external fab capacity is not increasing as suppliers play it safe.”

A B I R e s e a r c h ’s Wo r l d w i d e Semiconductor Market Tracker shows that global semiconductor growth has also seen signs of an overall fall. 4Q11 revenues fell to US$71 billion, after

being relatively stable at between US$76.5 billion and US$79.5 billion from 3Q10. 1Q12 and 2Q12 revenues were relatively flat and an overall market decline is expected for 2012 of up to five percent.

As inventories are burnt and order books become less predictable, the ability to bounce quickly on any upturn will be limited. Upcoming debt ceiling decisions in the US, US presidential elections, the Euro debt crisis, and the lack of availability of credit facilities are likely to create a situation whereby manufacturing and semiconductor production are squeezed through the end of 2012 and into the middle of 2013 at the very least.

London, UK: In the first 10 years of its life (up to 2010) cumulative shipments of Bluetooth enabled devices reached five billion. Growth has been largely driven by its use in mobile phones and accessories. This market is still growing overall but it will start to plateau out over the next five years. So, will Bluetooth become obsolete before the end of its second decade?

The Bluetooth SIG has regularly introduced updates to the technology to increase its use cases and continue growth of the market, for example v2.1 with enhanced data rate was introduced in 2007 and v3.0 with “high speed” was introduced in 2009. These have both helped to push the envelope for Bluetooth technology but it’s v4.0 – low energy Bluetooth – (introduced in 2010) that is set to revolutionise the technology and drive expansion into new markets.

“The introduction of Bluetooth v4.0, with low energy as its pivotal enabler, will drive a second wave of Bluetooth enabled device shipment growth” said Peter Cooney practice director, of semiconductors, “the market is expected to achieve cumulative shipments over 20 billion by 2017.”

There are essentially two separate implementations for Bluetooth v4.0; one is single-mode Bluetooth v4.0 or Bluetooth Smart and dual-mode Bluetooth v4.0 or

Brano Hudak, Kosice, East, Slovakia

Bluetooth Smart Will Drive Cumulative Bluetooth Enabled Device Shipments To 20 Billion By 2017

Bluetooth Smart Ready. Bluetooth Smart Ready devices are already available eg: Apple iPhone 4S and Samsung Galaxy SIII. These are the hub devices that enable Bluetooth Smart devices such as sports and fitness sensors to communicate with the wider world.

The first markets to embrace Bluetooth Smart Ready are smartphones, media tablets and laptops but growth in TVs, games consoles, and in-car infotainment systems will follow. Bluetooth Smart watches, heart rate monitors, and even shoes are already available; initial growth will be driven by sports and fitness devices with future growth markets including healthcare, PC peripherals, remote controls, and many more.

September 2012 | industrial automation asia 13

Industry News

Microchip Technology Announces Receipt Of Antitrust Clearance From China For SMSC Acquisition

Petria Follett, Brisbane, Qld, Australia

Chandler, US: Microchip Technology Incorporated, a provider of microcontroller, analogue and FlashIP solutions, has received notice of clearance of its previously announced acquisition of Standard Microsystems Corporation (SMSC) from the AntiMonopoly Bureau of the Ministry of Commerce of the People’s Republic of China.

“We are pleased that receiving the confirmation from MOFCOM completes all of the regulatory approvals for the transaction to acquire SMSC,” said Steve Sanghi, president and CEO.

Lunarline Showcases Products At The Eighth Annual IT Security Automation Conference Virginia, US: Lunarline will showcase its cyber security product capabilities at the Eighth Annual IT Security Automation Conference. The conference will be held at the Baltimore Convention Center on October 3, 4, and 5, 2012. Lunarline's showcase, located at booth 19, will provide live demos of the following: • Continuous Compliance Monitoring & Reporting (CCMR) Solution: A tool suite designed to centralise risk management and monitoring of both the security state of an information system and its compliance with regulations. CCMR allows customers to leverage their existing security tool investments and provides a flexible framework to incorporate new or existing data feeds into the monitoring framework.

• SCAP Sync: A search engine and repository for Security Content Automation Protocol (SCAP) content. It synchronises SCAP content on a daily basis, then syndicates that content in a number of user-friendly and machine-readable formats. It creates efficiencies by making SCAP more relevant and usable for everyday security practitioners and application developers. Attend our speaker session, ‘Demystifying SCAP with SCAP Sync Repository and API’, at 2:15-3pm on October 3, 2012.

14 industrial automation asia | September 2012

• Lunarline Cyber Intelligence Console: A front-end user console that was designed to work with the intelligence report feeds from iSIGHT Partners. The console ties intelligence reports to a customer's assets and provides an enterprise risk score based on the priority level of assets and the severity score of reports. The console also provides the ability to easily navigate through and filter reports to facilitate risk assessment and decision-making.

The company’s development philosophy aligns with the larger Federal shift toward modularised automated security tools that can work together to provide 360-degree security coverage. All of our tools are designed to provide our customers with ‘a la carte’ options to build their defense-in-depth solution -- the days of ‘rip and replace’ solutions are gone. The SCAP standards have greatly facilitated the shift toward this modular approach.

The eighth annual IT Security Automation Conference, co-hosted by the National Institute of Standards and Technology (NIST), will focus on the breadth and depth of principles and technologies designed to support computer security automation for organisations in both the public and private sectors. The conference will be held October 3-5, 2012 at the Baltimore Convention Center in Baltimore, Maryland, US.

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ENQUIRY NO. 483

Bundle B • TIA Portal V11 Basic • SIMATIC S7-1200 CPU 1214C • SIMATIC HMI KTP600 Basic Color SIMATIC STEP 7 V11 is an integral component part of the centralized Totally Integrated Automation Portal engineering framework. It has a uniform operator input concept across all automation tasks with shared services (e.g. configuration, communication, diagnostics), as well as automatic data consistency.

The SIMATIC S7-1200 system can be extended to meet any machine’s requirement. The digital and analog I/Os can easily be expanded without affecting the physical size of the controller by installing a signal board inside the front of the CPUs. The CPU 1214 C can accommodate up to eight signal modules.

The KTP600 Basic color offers a 5.7 inch Touch Display and additionally 6 tactile keys. The choice of Panel for HMI tasks of limited complexity yet enhanced requirements in visualization for the use in PROFIBUS or PROFINET networks according to the chosen variant; especially when used alongside SIMATIC S7-1200 controllers among other controllers.

siemens.com.sg/TIABundle Email: industry.sg@siemens.com

Industry News

Washington, US: Total subsidies for renewable energy stood at US$66 billion in 2010, but are still dwarfed by the total value of global fossil fuel subsidies estimated at between US$775 billion and more than US$1 trillion in 2012, according to new research conducted by the Worldwatch Institute for its Vital Signs Online service. Although the total subsidies for renewable energy are significantly lower than those for fossil fuels, they are higher per kilowatt-hour if externalities are not included in the calculations, write report authors from Worldwatch's Climate and Energy team.

According to projections by the International Energy Agency (IEA), if fossil fuel subsidies were phased out by 2020, global energy consumption would be reduced by 3.9 percent that year compared with having subsidy rates unchanged. Oil demand would be reduced by 3.7 million barrels per day, natural gas demand would be cut by 330 billion cubic metres, and coal demand would drop by 230 million tonnes of coal. And the effects of the subsidy removal would extend beyond the end of the phaseout period. By 2035, oil demand would decrease by 4 percent, natural gas by 9.9 percent, and

coal demand by 5.3 percent, compared with the baseline projection.

Overall, carbon dioxide emissions would be reduced by 4.7 percent in 2020 and 5.8 percent in 2035. The IEA's chief economist estimated that eliminating all subsidies in 2012 for coal, gas, and oil could save as much as Germany's annual greenhouse gas emissions each year by 2015, while the emission savings over the next decade might be enough to cover half of the carbon savings needed to stop dangerous levels of climate change.

Progress toward a complete phaseout, however, has been minimal.

The 2009 pledge by the Group of 20 major economies to reduce ‘inefficient fossil fuel subsidies’ has been left vague and unfulfilled. The lack of a definition has left countries to make their own determination if their subsidies are inefficient. As of August 2012, G20 countries had not taken any substantial action in response to the pledge while six members opted out of reporting altogether (an increase from two in 2010), and no country has yet initiated a subsidy reform in response to the pledge. Furthermore, there continues to be a large gap between selfreported statistics and independent

Asif Akba, Hungary

Fossil Fuel And Renewable Energy Subsidies On The Rise

estimates in some countries.

Some argue that reducing subsidies would disproportionately affect the poor. An IEA survey of 11 developing and emerging countries, however, found that only 2-11 percent of subsidies went to the poorest 20 percent of the population, showing that subsidies tend to be regressive.

Fossil fuel subsidies continue to far outweigh support for renewable energy.

Although independent reporting on these subsidies has increased, global efforts to move forward with subsidy reform have been hindered by a variety of causes, leaving international pledges unfulfilled.

Ducon Tops The List Of Indian-Owned Companies In America New York, US: Ducon Technologies has announced that its latest study of Indian-owned companies operating in North America, Ducon clinched the top spot. The study was conducted by an Indian publication based in New York, US. The company was ranked number one among the top one hundred companies with its annual sales of over US$462 million.

The company is a global provider of advanced and custom engineered environmental control, material handling and energy systems to utilities and other industrial concerns since 1938. Over the years the company has

16  industrial automation asia | September 2012

secured 35 patents in the field of environmental control and materials handling. Since its inception, Ducon has compiled over 30,000 completed installations in a variety of industries including: chemicals, pulp and paper, steel, textile, mining, fertiliser, food, power, coal and petrochemical along with state and federal governments.

The company is headquartered in New York, US, having 19 sales and engineering offices across the US and foreign subsidiaries in India and China, with licensees and sales agents in major industrial parts of the world.

Industry News

ABB To Help Increase Production, Energy Efficiency For Century Cement In India

Texas, US: Merrick, a provider of production management and accounting solutions to the upstream oil and gas industry, will open an office in Colombia (Merrick Colombia SAS), in Bogota.

Establishing a presence in Colombia will enable the company to better serve its customers and partners with Merrick Production Manager, an end-to-end solution for production management and hydrocarbon accounting, and provide local assistance for oil companies operating in Colombia to monitor and improve production operations and results. The company’s software is optimised for onshore/offshore as well as both conventional/unconventional, and is as such well suited for the Colombian market.

“With regional presence and local expertise, we are better able to serve our Colombian clients. We are excited to join the rapidly growing oil and gas community in Colombia and bring our knowledge and experience, built over two decades of serving the industry, into this market”, stated Samina Farid, co-founder, executive VP and COO, Merrick.

Jason Antony, Vancouver, BC, Canada

Zurich, Switzerland: ABB has won an order worth US$18 million in India to design, engineer and supply integrated automation and modern electrification systems for Century Cement’s Manikgarh Cement plant in central India.

Manikgarh Cement is located in the State of Maharastra, in central India, and provides high quality cement products for building construction, road and bridge infrastructure and other commercial uses. ABB’s delivery is part of a two line expansion and plant modernisation project that will add production capacity of 2.8 million tonnes of cement per year, more than doubling its current production. The project also includes a 60 MW thermal power plant onsite.

The company will provide manufacturing technology to expand production capacity and maintain high product quality while providing an on-site power supply that will improve energy efficiency.

The company will deliver integrated power and automation systems using a

plant-wide 800xA automation system to control, connect, and optimise the performance of all processes and systems. The scope of supply includes medium-voltage switchgear, distribution transformers and other electrical equipment and power systems, intelligent low-voltage motor control centres, variable speed drives, instrumentation, and collaborative production management systems. It will also provide design, engineering, project commissioning, and other site services.

Zayo Group Purchases Remaining Interest In US Carrier

Rotorhead, Norway

Bogota, Colombia

David Garzon, Bogota, Cundinamarca, Colombia

Merrick Establishes Colombian Subsidiary In Bogota

Louisville, and Atlanta, US: Zayo Group has agreed to purchase the remaining ownership interests in US Carrier Telecom, a regional fibre-based bandwidth services provider with a network that spans Georgia, Florida, Alabama and Tennessee. The company acquired an approximately 50 percent

interest in US Carrier through its acquisition of American Fibre Systems in October 2010. The company will purchase the remaining interests in the company from its current shareholders for US$13.5 million.

US Carrier operates a 3,700-mile regional fibre network that connects major markets such as Atlanta, Jacksonville, Tallahassee, Nashville and Chattanooga along with 40 smaller cities throughout the Southeast, such as Macon and Savannah, Georgia and Mobile and Montgomery, Alabama.

It provides transport services such as Ethernet and Wavelengths primarily to other telecommunications providers who leverage this network.

September 2012 | industrial automation asia 17

Industry News

Tokyo Electron To Acquire FSI International Tokyo, Japan & Chaska, US: Tokyo Electron Limited (‘TEL’) and FSI International have entered into a definitive agreement under which TEL will acquire FSI for US$6.20 per share in cash, or an aggregate equity purchase price of approximately US$252.5 million.

The purchase price represents a premium of 53.5 percent to the closing price of FSI's common shares on August 10, 2012. The acquisition, which will be completed pursuant to a cash tender offer followed by a second step merger, has been unanimously approved by the boards of directors of TEL and FSI. The board of directors of FSI unanimously recommends that FSI’s shareholders tender their shares into the tender offer. The transaction

is expected to close in calendar year 2012.

Surface preparation has increasingly become a critical technology in semiconductor manufacturing, and TEL is focused on improving its market position. FSI is a provider of cleaning and surface preparation equipment with process capabilities complementary to TEL’s. FSI’s technologies, combined with TEL’s expertise and track record as a provider of batch and single wafer surface preparation equipment with high productivity and low defect performance, will enable TEL to provide a stronger overall product lineup. Additionally, the diverse set of tool capabilities enhances TEL’s capacity to offer value-added solutions for the new surface preparation

challenges that will inevitably come in the future.

Under the terms of the definitive merger agreement between TEL and FSI, TEL, through an indirect whollyowned subsidiary, will commence a cash tender offer to purchase all of the outstanding shares of FSI’s common stock for US$6.20 per share. The closing of the tender offer is subject to customary terms and conditions, including the tender of a number of shares that constitutes at least a majority of FSI’s outstanding shares of common stock, on a fully diluted basis, and receipt of required regulatory approvals, including expiration or termination of the waiting period under the Hart-Scott-Rodino Antitrust Improvements Act.

Global Bring-Your-Own-Device (BYOD) And Enterprise Mobility Market Worth US$181.39 Billion By 2017 Texas, US: According to a new market research report, ‘Bring-your-own-device (BYOD), Consumerimization of IT (Co-IT) and Enterprise Mobility Market - Global Advancements, Business Models, Market Forecasts & Analysis (2012 - 2017)’, published by MarketsandMarkets, the total BYOD and Enterprise Mobility market is expected to reach US$181.39 Billion by 2017 with a CAGR of 15.17 percent.

BYOD and Enterprise Mobility concept is getting huge traction in the technology market nowadays. This is one of the hot topic in the market after cloud computing.

The reason behind the market growth is that, enterprises are going mobile and they need to be in touch with their mobile workforce anytime anywhere. Companies are getting instant return in terms of visibility, time management, cost saving, and positive work environment.

Employees are using their own devices such as smart phones, tablets, and laptops, for the official work to be connected with the enterprise network anytime, anywhere.

As such BYOD phenomenon is entering enterprise IT, and will change the way users and organisations address the network security concerns.

Employees want to use the device which they would like to use. The organisation is not forcing them to do so.

BYOD and Enterprise Mobility is allowing them to use the

18 industrial automation asia | September 2012

same. There are software and security vendors which are helping the companies to provide an environment where employees can connect their devices to the enterprise network without having any security related issues and this is driving the growth of the BYOD and enterprise mobility market.

Global BYOD & Enterprise Mobility Market is expected to grow from US$67.21 billion in 2011 to US$181.39 billion by 2017, at an estimated CAGR of 15.17 percent from 2012 to 2017.

North America commanded the largest share; ie: 36.10 percent of the overall managed BYOD and Enterprise Mobility Market in 2011 at US$24.26 billion; and is expected to reach US$58.60 billion by 2017, at a CAGR of 12.9 percent from 2012 to 2017.

In addition to market sizes and forecasts, the report also provides a detailed analysis of the market trends and factors influencing market growth, offering in-depth geographic analysis of the BYOD & Enterprise Mobility Market in North America, Europe, Asia-Pacific, Latin America and Middle East & Africa. The report draws the competitive landscape of the bring-your-own-device market, providing an in-depth comparative analysis of the technological and marketing strategies. The key players are adopting in order to gain an edge over their competitors.

IAA has the momentum and is making changes to further serve our clients in the industry.

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Industry Updates

Profibus/Profinet Seminar Held At Biopolis, Singapore The Profibus/Profinet Association South East Asia has conducted a successful Profibus/Profinet seminar in Singapore at Biopolis.

A total of 150 people attended.

The Seminar was supported

by Siemens, Pepperl + Fuchs, ABB, VEGA, Endress & Hauser, Rovisys, Leoni Cable, Bartec, Harting, Phoenix Contact, Lapp Cable and Turck. These companies provided live demonstrations of their products and solutions at a Microfair, giving seminar participants the chance to discuss these face to face with experts.

For the first time the brand new Profinet multivendor demo was introduced. This showed the wireless integration of Profibus-DP/PA into Profinet, also the integration of different products and protocols. The live engineering of an IO-System was demonstrated along with Profinet’s web diagnostic functions.

Three Parts The seminar had three parts; news and market updates on Profibus/ Profinet; a Profibus Block, with presentations on installations and best practices; and a Profinet Block with presentations on innovative Industrial Ethernet solutions as well as the new features available.

Bernd Lieberth, president of the regional Profibus/Profinet Association, presented latest news, including the world sales figures. Profibus increased its installed base by five million nodes in 2011, which means the total 20 industrial automation asia | September 2012

installed base is now in excess of 40 million nodes. Profinet also grew, from three million nodes last year in 2010 to four million nodes in 2011. He also introduced the PROFIenergy profile, which is the first networking standard for energy management and energy saving. The standard runs on Profinet.

Teo Puay Yong (Pepper + Fuchs) presented best practice and regulations for setting up a Profibus network based on his many years of experience with real installations.

In Conclusion The day ended with presentations on Profinet from Mr Lieberth (Siemens) and Emmy Lim (Phoenix Contact). With Profinet, PI has developed a comprehensive industrial Ethernet networking

standard from the experience gained from Profibus. The result is open and manufacturer neutral. Profinet meets all of the requirements for using Ethernet at all levels, and in all automation applications. It is flexible, reliable and robust in any industrial environment. Profinet offers new possibilities too, such as redundancy, shared device, intelligent devices, wireless connectivity and much more.

The seminar in Singapore is part of a continuing seminar series in ASEAN countries. Mr Lieberth said: “We achieved a high participation rate thanks to the support of our members. We will continue our seminar series this year, with Vietnam and Indonesia on the schedule.”

ENQUIRY NO. 6101

Newsdesk

Anniversary Conference In Seoul CAN in Automation (CiA) has released version 2.1 of the CiA 417 CANopen application profile for lift control systems. The new version of the four-part specification provides some functional extensions. It is backward compatible to the predecessor.

Besides some additional emergency error codes, the power-measuring unit has been added. Another enhancement is the standardised boot-up and program download procedure. The specifications have been reviewed, some minor editorial failures have been corrected, and some editorial improvements have been introduced, too.

The CANopen Lift application profile is the only ‘open’ communication standard for embedded lift control systems. It provides a migration path from proprietary to ‘open’ control systems. It is also possible to ‘open’

just a part of the control system. The newly introduced power-measuring unit is a tribute to the energy efficiency requirements. In one control system, there may be installed two of these units. One of them could be embedded in the drive unit, and the other one measures the energy consumption of all other control devices. If the energy consumption increases during the lifetime of the system, in particular of the drive unit, this will be detected and it can be exchanged against more efficient one. The measured values are transmitted by means of MPDOs or can be read via the default SDO server. It is not standardised, who consumes the measurements. Normally, it is the controller device with the call controller functionality.

ENQUIRY NO. 6102

CAN And CANopen Seminars Ixxat (Germany) has scheduled three seminars to be held in Weingarten, Germany. They are dedicated for design engineers.

The company providing CANopen protocol stacks, CAN tools, and interface boards as well as gateways offers also seminars on CAN and CANopen technology. Besides in-house seminars, there are also scheduled trainings open for everyone. Seminar language is German. In the CAN seminar on

September 25, 2012, the participants learn in detail the CAN physical layer options and the CAN data link layer protocol. The following day, the topic is analysing CAN networks by means of tools. The third seminar, held on September 27, 2012, deals with the CANopen application layer and the CANopen profiles. All three events can be booked individually.

ENQUIRY NO. 6103

David Hart, Friendswood, Texas, US

CANopen Lift Profile Updated

Seoul, South Korea

Vector’s (Germany) subsidiary in South Korea celebrates its fifth anniversary with a conference in Seoul. This event provides four tracks covering all topics of CAN networking and in-vehicle communication.

The conference will take place on September 25, 2012, and the language will be Korean and English (with simultaneous translation into Korean). The detailed program is available on Vector’s website. CiA sponsors one track of the conference.

In it the CAN FD protocol as well as the CANopen protocols and profiles will be introduced. The other tracks are dedicated for Engine Control Unit (ECU) testing, embedded software as well as diagnostics, measurements, and calibration.

Thomas Geyer, president, Vector Korea, expects that this conference will be the biggest event of its kind in South Korea. The participation is freeof-charge. Due to the limited seats an early registration is recommended.

ENQUIRY NO. 6104

September 2012 | industrial automation asia 21

Fieldbus Foundation Announces Latest Participant In Foundation Development Services Provider Program Fieldbus has qualified under its Foundation Development Services Provider (DSP) program. A solutions provider for fieldbus technology applications, product development, standard and custom function blocks, consulting, training and many other products and services. The company joins other qualified service providers in the program, which helps automation vendors get started with Foundation product development by making it faster and easier to bring fieldbus equipment to market.

The Fieldbus Foundation launched the Foundation DSP program to assist automation equipment suppliers preparing

Fieldbus Foundation Updates Foundation Fieldbus Device Coupler Test Specification The Fieldbus Foundation has announced the latest updates to its open, non-proprietary Foundation fieldbus physical layer technology. Current enhancements to the H1 (31.25 kbit/s) device coupler test specification will help improve the reliability and availability of fieldbus control system installations, as well as optimise device interoperability and integration.

As part of a Foundation fieldbus infrastructure, device couplers or isolated device couplers (where applicable) are installed where the fieldbus trunk (ie: home run cable) is connected to the various device spurs. Isolated device

22  industrial automation asia | September 2012

to design and manufacture products employing Foundation fieldbus technology. The DSP program is intended to provide access to qualified development services providers with the know-how to make fieldbus solutions a reality. Qualified DSP participants have been evaluated to ensure they have the tools, training and experience necessary to support a wide range of Foundation fieldbus development projects. Services that can be qualified in the Foundation DSP program include H1 and High Speed Ethernet (HSE) fieldbus device development services, as well as host system services.

Tom Boyd, VP, engineering, Fieldbus, said: "As a recognised expert in field communication technologies for the process automation industry, a key participant in the development of fieldbus product solutions and an active member of the Fieldbus Foundation, Fieldbus sought the DSP qualification to continue our support of the technology and the manufacturers wanting to use it. The DSP program is an excellent way to expand our role as a high-quality Foundation technology provider."

ENQUIRY NO. 6105

couplers are specifically designed to allow automation end users to connect more devices per coupler while permitting live segment work in hazardous plant areas. These couplers provide isolated, conditioned power to multiple fieldbus devices and protect against short circuits caused by excess current in a spur. By enabling more devices per segment, they also help reduce controller input/output (I/O) points and associated installation costs.

The Foundation fieldbus device coupler test specification includes criteria from the international IEC 61158 standard and additional functional tests such as input impedance, short-circuit reaction time, and bus voltage consumption. The specification is designed for coupler manufacturers to perform a standard set of tests against their implementation. A team of volunteers comprised of current members of the foundation who supply coupler products, as well as end users employing registered couplers, developed the test cases.

ENQUIRY NO. 6106

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息2012 Honeywell International, Inc. All right reserved.

ENQUIRY NO. 459

Member Meetings In South Korea And Japan At its regional member meetings in Korea and Japan the EtherCAT Technology Group (ETG) provides updates about the latest technological developments and the group’s worldwide activities. Furthermore, notable EtherCAT applications demonstrating user benefits are presented by local members.

Like in the previous years, around 120 Japanese ETG members attended the meeting in Yokohama, Japan, which emphasises the high level of interest in the EtherCAT technology within the Japanese automation community.

One highlight of the meeting was the presentation from rapid prototyping specialist ExOne Asia: the company introduced an EtherCAT-powered 3D printer that generates sand casting molds for precisely-crafted metal parts. Due to PC-based controls with EtherCAT, the cycle time of the machine is now half than that of the previous solution, substantially increasing both productivity and accuracy.

The South Korean meeting held in Seoul was again attended by over 80 participants representing the country’s EtherCAT users as well as its EtherCAT device vendors. Daewoo Shipbuilding and Marine Engineering presented their new EtherCATbased portable welding robot. The six-axis robot is extremely lightweight and can even be carried by a worker. Once placed in the ship body’s U-type cell, it uses a variety of sensors to learn its exact position and orientation and to find the welding points.

The worker selects the welding program and starts the robot, which then moves along the cell and welds autonomously for up to 30 minutes, before it needs the worker’s attention again. The robot controller is located in a movable enclosure up to 50m away from the robot itself; it controls the EtherCAT drives which are located within the robot body.

ENQUIRY NO. 6107

120 Participants representing around 75 of the 240 Japanese ETG members attended the member meeting in Yokohama, Japan.

ENQUIRY NO. xxxx

Daewoo presented their EtherCAT-based portable welding robot at the ETG member meeting in Seoul, South Korea.

Techno Frontier Show In Japan Large crowds blocked the aisle when Masanori Obata, ETG representative Japan, presented on EtherCAT technology at the 2012 Techno Frontier Show in Tokyo. The ETG booth was organised jointly by the members of ETG regional committee Japan and the ETG Japan office. The booth was supported by many co-exhibitors, showing mainly Japanese EtherCAT products.

In parallel to the show, an introductory EtherCAT seminar was held, which was attended by 70 interested listeners.

Masanori Obata draws a crowd when he presents EtherCAT at the 2012 Techno Frontier show in Tokyo, Japan.

24 industrial automation asia | September June/July 2012 2012

ENQUIRY NO. 6108

EtherCAT Activities In China: Exhibitions And Seminars A larger ETG joint booth was introduced at the 2012 edition of Industrial Automation Beijing, the successor of the FA/PA exhibition. Both Chinese and foreign automation vendors displayed their EtherCAT devices, generating interest in these products as well as in the nuances of EtherCAT technology.

The booth was well attended: EtherCAT is used in many applications in China, ranging from power generation to machine tooling.

ENQUIRY NO. 6109

The ETG booth at the Industrial Automation show in Beijing, China.

EtherCAT Seminars In Malaysia And Singapore The ETG is coming to Malaysia and Singapore, in October 2012, to hold educational seminars. These events address the needs of users and system integrators alike, who must decide if, when and how to switch from traditional fieldbus systems to modern Industrial Ethernet technologies.

The seminars are held by automation experts who will provide a deep insight into the technology: the functional principles of EtherCAT are explained together with its impact on system architecture, costs and application performance. The agenda focuses on the user point of view: how EtherCAT can help machine builders and system integrators alike gain competitive advantages in their markets. Applications are introduced

ETG seminars are educational technology events.

and discussed, without lengthy product presentations.

The seminars in Malaysia are full day events, while the Singapore seminar is a half day. Participation is free of charge since the seminars are sponsored by Beckhoff Automation, the company that invented and originally introduced EtherCAT.

Dates and locations: • Oct 15, 2012: One World Hotel Selangor, Kuala Lumpur, Malaysia.

• Oct 16, 2012: Hotel Equatorial, Penang, Malaysia.

• Oct 17, 2012: Swissotel Merchant Court, Singapore ENQUIRY NO. 6110

September June/July 2012 | industrial automation asia 25

issues & insights

Are You Sending People In Harm’s Way? Y

our plant may have many potential hazards for personnel. Many protective measures can be taken to reduce risk. One important measure is to reduce the exposure time to potential hazardous situations by not sending people into the field as often, and for the shortest time possible. This can be achieved by reducing manual tasks such as finding and reading gauges, sight glasses, and variable area flowmeters manually during field operator ‘clipboard rounds’.

Tank level gauging by means of dip stick should also be minimised, as it requires the field operator to climb the tank, open the tank hatch, and expose themselves to vapors.

The more time operators

26 industrial automation asia | September 2012

have to spend in the field making their rounds for timely data, the greater the risk to their safety.

The measurement ‘update period’ depends on how often the field operator makes the rounds in the plant which may be as infrequent as once per shift, day, week, or even month or longer.

An additional issue with manual readings is that they are prone to inaccuracies. The typical accuracy of a pressure gauge is only one percent and the typical temperature effect is 0.4 percent per 10 deg C adding further inaccuracy. Gauges have moving mechanical parts which will fail with time, resulting in reliability which is only ‘fair’. A corroded gauge may get stuck, no longer responding to process

Robert Proksa, Jaworzno, Slaskie, Poland

Your most important asset is people. Therefore plants strive to reduce the amount of time personnel spend in harm's way. The amount of time operators work in the field can be minimised by automating manual tasks such as clipboard rounds for collecting data.

Modernisation with WirelessHART enables new automation in existing plants with minimal risk By Jonas Berge, director, Applied Technologies, Emerson Process Management

changes, providing a false and misleading reading which may go undetected for long periods of time. Inaccuracies may also result from human factors such as parallax error when reading the gauge, mistakes writing the log sheet, errors due to illegible handwriting, and typographical errors when entering data into software.

One solution to these problems is to replace gauges, sight glasses, and variable area flow meters with wireless transmitters for pressure, temperature, level, flow, and many others to measure and transmit the reading wirelessly back to the control and asset management systems. Data can be transmitted as often as once per second, once per minute, once per hour, or

diagnostics and so on. Additionally, the calibration of the reader to the gauge must be maintained to ensure that the reading is true.

Portable Testers Condition-based maintenance routines rely on maintenance personnel periodically inspecting

the health of assets such as pumps and motors. This includes carrying an arsenal of portable vibration tester, infrared temperature gun, and ultrasonic tester for steam traps into the field. The limitations of portable testers are similar to that of manually reading gauges.

An additional problem is that

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ENQUIRY NO. 452

anything in between as required by each application. This eliminates the need for technicians to make rounds reducing the time spent in the field, and thereby reducing risk. Note that there is no need for a one second update rate for every measurement. Something that was never checked before, or logged just once a day or less, does not have to be measured once every second now. A one minute update period is most common, and more than a thousand times faster than a daily inspection, and five orders of magnitude more frequent than monthly inspection.

A wireless pressure transmitter has a basic accuracy of 0.065 percent with a temperature effect as little as 0.14 percent per 28 deg C. Since the data collection is totally automatic, human errors in reading, writing, and typing are eliminated. Console operators get the measurement directly in the control system. Built-in device diagnostics detect sensor health, validating the reading or flagging for problems such as sensor failure or exceeded operating conditions.

Sensors have no moving parts and are therefore very reliable.

Start the plant modernisation by replacing gauges at locations included in the log sheets for the field operator’s clipboard rounds.

Level can be measured using a wireless differential pressure transmitter, wireless point level switch, or a conventional radar level transmitter fitted with a WirelessHART adapter. Level readings will periodically be transmitted to the system as often as configured.

Wireless ‘gauge readers’ mounted on the face of a mechanical dial gauge to read the position of the needle can also eliminate manual readings but retain many of the problems associated with mechanical gauges such as inaccuracy, temperature effect, poor reliability, and no

September 2012 | industrial automation asia 27 DensoRoboticArmAd.indd 1

25/5/12 4:36 PM

issues & insights

WirelessHART analyser for pH or conductivity

pumps which are not in continuous service or are variable speed may not be running or at the appropriate loading at the time of inspection. If checks are scheduled on a monthly basis, it will be yet another month before the next check.

Wireless vibration transmitters can be installed instead of using portable testers. An update period of one hour gives more than seven hundred times better temporal resolution than monthly inspection. Wireless monitoring will reduce field visits, and also provide the ability to spot trends as vibrations worsen and correlate vibration to operating conditions.

Wireless acoustic transmitters monitor the health of steam traps without having to send personnel into the field to inspect them.

A one minute update period is half a million times more frequent than yearly inspection. Acoustic transmitters are also used to detect if pressure relief valves have been activated.

Valves Hand operated valves left in the wrong position could be a hazard, resulting in spills or even fires. Therefore operators may be sent to the field to confirm actual valve position. Batch operation or loading/unloading may require many hand valves to be lined up correctly.

A built-for-purpose WirelessHART valve position monitor can be installed on linear and rotary valves to provide valve position feedback to the central control room. For very long stroke valves, conventional proximity limit switches can be used with a wireless on/off contact input transmitter.

The feedback can be a part of the automatic batch sequential logic permissives and interlocks.

Grab Samples Another example of manual operator field tasks is the collection of product grab samples or effluent to be brought back for lab analysis. This manual sampling process requires field visits and handling of liquid samples.

Wireless conductivity and pH

Meeting User Needs There are many wireless technologies which attempt to help automate sites. WirelessHART meets basic requirements like selectable update period down to one second, multiple security measures including encryption, authentication, verification, key

28  industrial automation asia | September 2012

transmitters take the place of this practice. For other measurements, conventional analysers fitted with a WirelessHART adapter can instead be used.

rotation, and sequence number, as well as coexistence with other wireless networks and radios through spread spectrum, channel hopping, and channel blacklisting.

Other basic requirements like battery life up to 10 years, as well as third-party interoperability testing are also met.

Additionally, WirelessHART provides unmatched availability and reliability thanks to a full multihop, multi-path mesh topology, which allows a single, optionally redundant gateway instead of having to install and wire up an infrastructure of multiple backbone routers throughout the plant.

Unique WirelessHART security f e a t u re s i n c l u d e a l w a y s - o n security and secure provisioning using a common HART handheld field communicator connected to the console port on the device. WirelessHART provides unequalled interoperability and interchangeability through a common standard protocol, which together with Electronic Device Description Language (EDDL) also results in unrivalled ease of integration in control systems. WirelessHART is the only wireless protocol which allows the transmitters to be commissioned using the handheld communicators that plants already have and are familiar with.

Deployment By not having to send field operators into the plant, WirelessHART improves personnel safety and productivity. Timely measurements provide a better understanding of the process and assets for troubleshooting, and ability to spot developing tendencies. Thanks to full multihop, multi-path mesh topology, WirelessHART can be used to modernise plants with minimal risk to the existing installation.

ENQUIRY NO. 6201

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491

issues & insights

Daniel West, Sacramento, CA, US

Next-Generation ISA100 Plant Wide Wireless Solution

Reliable, flexible, and open communication is of key importance to an effective communications infrastructure in today’s industrial plants. ISA100.11a represents a step forward in industrial wireless for the industry. By Masaaki Matsuzaki, manager of wireless solution department, Yokogawa Electric

I

SA100.11a is an industrial w i re l e s s o p e n s t a n d a rd , which is reliable, flexible and deterministic communications protocol that helps streamline and optimise the integration of industrial processes’ automation applications. This advanced protocol makes it easier for different equipment and systems to communicate and work together.

The ISA100 family of standards is an end user-driven, complementary family of standards that address important marketplace requirements. The ISA100.11a standard was approved in September 2009 by ISA100 Industrial Wireless Standards Committee. Yokogawa, a founding member of ISA100 wireless 30 industrial automation asia | September 2012

standard, launched the world’s first wireless field products conforming to the ISA100.11a standard in 2010. In 2012, the company released a large-scale, reliable, next-generation plant-wide field wireless system. In developing this system, which forms the core of field digital solutions, the focus has been on the following three key features.

1 Reliability: reliable high-

performance field wireless and redundant technologies 2 Flexibility: flexible architecture that supports the full range, from small to large-scale plants 3 Openness: open ISA100.11a standard that allows third-

party field wireless devices to be connected This new system is developed in line with the company’s ‘Grow’ concept of helping customers to grow and enabling it to evolve and continue to offer timely and sustainable solutions.

Advantages Of The Next-Generation Field Wireless System Although most field wireless systems are currently installed in relatively small areas, demands are rising for increasing the number of monitoring points, covering wider areas, and expanding to process control as well as diagnosis, monitoring, and measurement.

To respond to these demands, the company has developed a large-scale, reliable, nextgeneration plant-wide field wireless system, which will manage up to 500 wireless field devices.

Conventional small field wireless systems are mainly installed as additional monitoring tools in areas with a clear lineof-sight such as tank yards and wastewater treatment facilities.

Such systems offer only limited advantages such as improved inventory management, reduced regular visual checking, automated environmental measurement, and reduced wiring costs.

In contrast, plant-wide field wireless systems can cover both a large number of measuring points in a small area packed with production equipment where

wireless devices are difficult to install, as well as the entire plant.

This allows customers to set up wireless devices anywhere in their plants and manage data from those devices to improve plantwide production efficiency.

Architecture Of The Large-Scale, Flexible, Field Wireless System The company has developed the following new products for this new plant wide field wireless system: • Field wireless management station • Field wireless access point • Field wireless media converter The company’s existing allin-one integrated field wireless gateway combines all the

New Generation Fanless Intelligent Systems Get the Job Done Efficiently

functions of access points and wireless management, enabling small wireless systems to be easily installed.

In the new architecture, the field wireless access point forms the wireless backbone network with the field wireless management station.

T h e re f o re , b y i n s t a l l i n g multiple field wireless access points throughout the plant, wireless sub-networks can be built and then connected to each other to create a large-scale, plant-wide field wireless system.

The field wireless access point and management station can communicate via Ethernet, o p t i c a l E t h e r n e t , w i re l e s s LAN, instrumentation cable communication, and so forth, allowing flexible installation in plants.

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September 2012 | industrial automation asia 31

issues & insights

wide field wireless system.

The Improvement Of Communication Quality With Detachable Antenna The detachable antenna type model has been released. The antenna extension cable and high-gain antenna can be used with this model. The placement of the antenna can be adjusted with the antenna extension cable without change the installation of transmitters. Furthermore the expansion of communication distance becomes possible with high-gain antenna.

Duocast

Technologies To Support A Highly Reliable Field Wireless System In the company’s system, the reliability of the network layer is enhanced with the import of new technology. The following two technologies are important elements of this system.

1 Duocast Duocast is a redundancy technology for the wireless path specified in the ISA100.11a standard. In the conventional mesh-topology network, if communication is not established in a path, data is then sent via another path.

However, this may affect real-time performance because the data is not sent in the same time slot, but in a later time slot even in the same superframe.

On the other hand, Duocast simultaneously sends two identical data in the same time slot, and provided either data is successfully transmitted, realtime performance is maintained.

Therefore, Duocast is suited for ensuring the redundancy of mission-critical wireless paths and helps improve reliability while securing low latency.

32 industrial automation asia | September 2012

2 Dual wireless backbone

network The network between the field w i re l e s s a c c e s s p o i n t a n d management station is called a wireless backbone network. Its redundancy is specified by the ISA100.11a standard to improve the reliability of the network and is achieved by the redundant f i e l d w i re l e s s m a n a g e m e n t stations. Either of the dual management stations can deal with disconnections and errors of the wireless backbone network, and malfunctions of the other management station.

Redundant field wireless management stations, one set to active and the other to standby, are connected with each other via a synchronous communication cable. If any trouble in the active station is detected, the functions and data are quickly shifted to the standby station to seamlessly continue the communication.

Enhanced Version Of Wireless Transmitters Wireless differential pressure/ pressure transmitter and wireless temperature transmitter have been enhanced with the release of plant

The Extension Of Battery Life With Low Power Consumption With enhanced design and processor, the battery life of the new model becomes longer than conventional products with low power consumption. Based on the scenarios, from 1.5 times to two times of battery life is realised.

The examples of the battery life are shown below.

Summary The company has been researching and developing industrial wireless technologies for 10 years and has compared a variety of standards, with the following conclusion: in adopting wireless systems in the fields of industrial measurement and control, wireless physical layers must eliminate instability as far as possible (Reliable Radio) and the system must reinforce it.

Among various industrial wireless communication standards, the ISA100 standards were the most suitable for achieving the company’s policy.

Therefore, it has adopted this standard and released the world’s first ISA100-compliant products to the market in 2010.

ENQUIRY NO. 6202

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ENQUIRY NO. 490

process control

M

oving large and heavy loads can, of course, be quite expensive. This applies in particular to tandem crane lifting with complex movements.

The US-based Control Chief Corporation has been supplying industrial, wireless control solutions for locomotives and material conveying applications for almost 40 years.

In the steel, coal and grain industries the company’s systems support the handling of large material quantities in different environments, including marshalling yards and ship loading. The application of radio remote control enables the positioning of operating staff in safe locations and optimises the efficiency of the operations.

Control Chief Corporation, based in Bradford, Pennsylvania, US, provides standard and customised solutions for controlling cranes and locomotives that are exactly tailored to customer requirements.

“Costs are a key factor for our competitiveness in the market, so that our solutions can affordably cover a

Case Study:

whole range of applications,” said Brian Landries, VP of sales and marketing, Control Chief.

PC-Based Control Replaces Traditional PLC “The vendor of the PLC that Control Chief used discontinued the line, so our future product development strategy needed to be reconsidered,” said David Persichini, product manager at Control Chief. “In addition to cost optimisation, our aim was to extend the technological capabilities of our control units,” he added. Towards the end of 2008 we started developing our ‘Triad’ control unit, with the aim of replacing the predecessor modules. It combines wireless communication, fieldbus networks and safety functionality.

In April 2010 the company used the Triad module for the first time for remote control of a locomotive in a coal mine: The task was to transport the coal from the mine over 17 miles (27 km) to barges for shipping.

“The central control system of the Triad module

From PLC To PC-Based Control Control Chief Corporation is a company, based in Pennsylvania, US, that provides solutions for controlling cranes and locomotives.The company explains why they decided upon PC-based control from Beckhoff Automation. By David Chia, MD, Beckhoff Automation (Southeast Asia)

Communication With Optimum Flexibility “The use of EtherCAT gives Triad unique flexibility,” said Mr Bryner. “Even though the EtherCAT network represents the most efficient integration with the Embedded PCs, our customers can choose between different fieldbuses and integrate them into their modular devices, instead of being limited to a single fieldbus, which used to be the case with our old PLC system.” The company integrated the EtherCAT protocol directly into the wireless Triad controller via an HMS Anybus module. Mr Bryner explains: “Via the EL6001 serial interface and the EL6752 DeviceNet master terminal Control Chief is able to use different fieldbuses in a flexible manner.”

All Functions Combined In A Single Programming Platform On the software side the company utilises the flexibility of the IEC 61131-3-compliant TwinCAT programming environment. “The possibility to choose between different programming languages within the same software is very convenient,” said Mr Bryner. “In the past, all functions of the wireless controllers — starting from the I/O control right up to the HMI and several external communication options — were developed in different software

Improved Performance, Lower System Costs, Reduced Development Time The new control platform was implemented very quickly: “It only took around six months from the start of the coal handling application project to create a functioning system with fully developed software,” said Mr Persichini. “An additional benefit of the wireless control system is the increased flexibility to apply different fieldbus systems, including EtherCAT. We therefore now use the control platform from Beckhoff in most of our control systems. To top it all, the new PC- and EtherCAT-capable wireless Triad controllers achieved around 30 percent in cost reductions on average,” said Mr Landries.

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ENQUIRY NO. 461

consists of a CX1010 Embedded PC from Beckhoff with the TwinCAT PLC automation software and EtherCAT I/Os. This provides a flexible and powerful control solution,” said Jake Bryner, technical director, Control Chief. A Beckhoff CP6907 Control Panel with 5.7-inch monitor and DVI/USB extended interface is used as operator interface.

Data transfer from the Triad unit to the portable Operator Control Unit (OCU) takes place via a radio module. Triad transfers the confirmed commands to the CX1010 and feeds the relay state data back to the OCU. TwinCAT processes the control commands of the OCU in conjunction with the locomotive data and guarantees safe control of the locomotive movements and safe loading and unloading of the coal. “The audio interface of CX1010 offers a functional expansion that enables us to issue voice warnings and alarm messages to the operator,” said Mr Bryner.

packages and had to be linked with suitable drivers.

TwinCAT PLC HMI CE now enables us to integrate the visualisation.”

“The option to combine all functions in a single programming platform is a big advantage,” said Mr Bryner. “In addition, customisation of the HMI, including diagnostic tools, troubleshooting, system setup and configuration, are now much easier.

Optionally, we can set up the control system via the control panel or via mechanical switches in the Triad controller,” he added.

Asif Akbar, India

The Triad control platform consists of a CX1010 DIN railmountable Embedded PC from Beckhoff, directly-connected EtherCAT I/Os, the TwinCAT PLC automation software platform and a CP6907 Control Panel with 5.7-inch monitor.

September 2012 | industrial automation asia 35

software & Networks

Optimising control panel layouts for noise mitigation in factory automation systems. By Dan McGrath, solutions manager, and Michael Berg, solution marketing manager, Panduit

For Industrial Automation

O

ne of the core issues affecting the performance and reliability of industrial control systems is electrical noise. The electrical noise emitted from sources such as Pulse Width Modulation (PWM) drives, power supplies, and hard switched inductive loads (relays/contactors) can adversely affect system efficiency and uptime by interfering with analogue signals, Industrial Ethernet transmissions, and Programmable Logic Controller (PLC) programs. The proliferation of high speed switching power systems found in today’s Variable Frequency Drives (VFDs) and servo motion systems is also introducing more noise into industrial systems.

Electrical noise (1) causes field devices to misread the environment; (2) causes devices to fail, reset, or enter a fault state; (3) can cause equipment damage; (4) results in signal retransmission that can inflict communication delays. These problems can be amplified by poor control panel layout practices or deficient grounding and bonding, and inadequate segregation of noise sources from susceptible devices. Designers may be inadvertently introducing productivity, quality, and even safety risks by following obsolete or misguided control panel layout practices that create electrical noise problems.

Converged Industrial Systems Can Be At Risk From Electrical Noise A fresh look at approaches to control panel layout can result in improved reliability and performance along with optimised usage of panel space. Three key strategies greatly improve control panel design:

36  industrial automation asia | September 2012

df df, df, US

Unified Physical Infrastructure Solutions 1 Follow a multi-layered electrical noise prevention

2

3

and mitigation strategy that optimises control panel space utilisation. Different layers should include grounding/bonding, separation, shielding, and filtering practices to provide optimal protection.

Implement an Ethernet layer leveraging TIA/EIA best practices yet protected from industrial risks (ie: shock and vibration, extreme temperature, chemical exposure). These practices include panel space and cable management and media and connectivity selection.

Leverage templates such as reference design and panel layout design tools to minimise engineering time, mistakes, and drive consistency.

A small investment in time spent up front creating improved designs can save many hours of time during installation, commissioning, and subsequent troubleshooting/maintenance during the operational lifetime of the system.

Types Of Electrical Noise Electrical noise is a very real threat to reliable, productive processing or manufacturing operations.

Several types of electrical noise can occur, and each requires solutions to mitigate or eliminate the problem. The types of noise differ in their frequency range and how the offending signals attach themselves to victims.

Noise Coupling Means And Mitigation Strategies There are three primary means for noise coupling that

Multi-Layered Approach To Noise Mitigation The National Security Agency first developed the concept of Defense in Depth (DiD) as a tactical approach to information and electronic security.

The same basic layering concept used in defending against a security threat can also apply to defending against the threat of EMI on critical communications and controls infrastructure. The following section describes the layers involved: inner layers are focused on preventing noise problems through proper bonding/grounding and segregation/ separation practices, and outer layers address mitigation of existing noise sources through shielding and filtering/suppression.

Grounding And Bonding Grounding and bonding is the foundation for controlling EMI in control systems. Because grounding is an NEC requirement for electrical safety, the sight of green and yellow ground straps,

ground bars, and PE conductors are common and relatively well understood.

However, a grounding system can be fully compliant and yet have equipment that encounters serious disruptions, stoppages, even damage due to an inadequately installed and engineered low impedance ground/bonding system for high frequency noise.

Three concepts of best practice control panel layout and design for this high frequency noise are: 1 Apply a proper ground plane 2 Deploy effective high frequency return path(s) 3 Install Braided Bond Straps

Separation And Segregation One of the easiest and least expensive ways to prevent noise problems is to lay out the control panel using segregation and separation techniques.

Segregation and separation is the practice of physically separating noisy circuits and devices from potential victims. Creating distance between sources and victims reduces the field strength of the noise and can eliminate or reduce the risk of

ENQUIRY NO. 478

can occur in control panels that can be mitigated if the underlying factors are identified and understood.

September 2012 | industrial automation asia  37

software & Networks

Separation Distances Past standard IEEE 518 (withdrawn in 2002) provided some guidance on the minimum distances between certain types of conductors in parallel runs based on noise susceptibility/generation. However, the evolution of power and signal wiring requires an update to this approach. ISO/IEC 24702, Generic Cabling for Industrial Premises, recommends the Mechanical, Ingress, Chemical, and EMI (MICE) classification to help designers select proper cabling.

Rather than defining separation distances, MICE defines the environmental conditions, including noise, where cabling will be installed. Proper cabling type is selected based on environmental class.

costly noise issues later on. However, this is in direct conflict with the desire to conserve panel space, so various shielding solutions have been developed that address this conflict.

When creating a panel layout, it is best to create physical, colour-coded zones in the panel to separate clean and noisy circuits. This approach also uses a zoned approach to allow easy identification of clean and dirty circuit areas within a panel by technicians: • Very Noisy/Dirty (black duct, at right side of enclosure) • Noisy/Dirty (light gray duct, at right side of enclosure) • Clean/Sensitive (white duct, at left side of enclosure) In addition, it is good practice to follow applicable codes for separating various voltage classes by providing separate wiring duct to avoid mixing high and low voltage cabling. Higher voltage devices should be mounted in the upper right-hand corner of the panel, keeping as much distance as possible from other electronic devices (such as PLCs, DC power supplies, and timers) positioned on the opposite left side of the panel. Also maintain distance between motor power and encoder, I/O, and analog cables.

38 industrial automation asia | September 2012

Barriers And Partitions When physical separation cannot be fully maintained, a conductive physical barrier or partition can be used to effectively provide wire segregation and shielding while reducing physical separation distance between wires. A metal barrier provides the greatest shielding protection from magnetic and capacitive coupled noise.

A metal barrier is capable of providing 20dB reduction in noise which is equivalent to up to six inches of air spacing. The value in reducing or eliminating the air spacing between the cables is to provide more optimal use of space within the enclosure. A noise barrier can also be used to enhance other noise mitigation efforts, including air spacing, for a defense in depth approach and a more robust controls system design.

Shielded Wire Ways (Trunking) Another method to provide wire segregation and shielding while reducing physical separation distance between wires is to use a shielded wire way or shielded trunking. This method is similar to a metal barrier but also provides a channel for routing larger wire counts and is fully enclosed for greater protection. A shielded wire way also is capable of providing a 20dB reduction in noise which is equivalent to up to six inches of air spacing. As with metal barriers the value in reducing or eliminating the air spacing between the cables is to provide more optimal use of space within the enclosure. A shielded wire way can also be used to enhance other noise mitigation efforts, including air spacing, for a defense in depth approach and a more robust controls system design.

Selection Criteria For Barriers, Partitions, And Shielded Wire Ways Selection criteria for a barrier or shielded wire way should include its material for relative conductivity and corrosion resistance and preferably will have performance data indicating its capability for EMI

Cable Shielding Options Shielded cables provide an important means of returning high frequency noise to the noise source.

The design of shielded cables and the proper termination of these cables require careful study of vendor recommendations and understanding of the system’s bonding and grounding design to avoid ground loops.

Cable shielding is important for both noise sources and noise victims. Preventing noise from escaping a controlled path to the noise source can reduce risk of disruption of sensitive cabling and systems. Shielded motor cables that are properly bonded at the noise source (eg: drive) and load (eg: motor) provide a controlled path for noise so it does not travel across unintended paths such as through a sensitive Ethernet cable that is in proximity.

Potential noise victims such as Ethernet cables also can benefit from shielding since it provides a low impedance path for the noise to travel rather than being coupled into the Ethernet signal conductors.

The shield becomes the path for noise to return to the noise source (eg: drive) rather than through the cable and the connected device (eg: PLC) so risks of communication disruption or device malfunction are reduced.

Filters And Suppressors Filters are used both to clean up signals or power

entering the panel as well as to prevent noise from a noise source from spreading within the panel. Filters provide means to selectively pass only the desired frequencies while returning noise frequencies to their source through a low impedance ground path.

However, if filters are not installed properly they can provide little or no benefit.

Key filter installation factors include: • Installation location — close to noise source or panel entrance to minimise length of unfiltered cable in the panel • Grounding — low impedance path. Ideally bond steel case to galvanised back panel.

• Cable routing — segregation. Avoid bundling line side and load of filter together so noise does not couple back from the dirty side to the clean side.

Suppressors are also used to redirect unwanted energy to inhibit noise coupling to sensitive circuits.

They are recommended to be used across dry contacts or inductive loads to short circuit the energy stored in relay or solenoid coils rather than allowing high voltage noise spikes to be developed. The noise spikes from opening a large coil can easily reach hundreds or thousands of volts and present a very real noise source that should be suppressed at its source.

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ENQUIRY NO. 368

noise reduction. The standard for performance is a barrier made from copper. However in application a corrosion resistant steel barrier provides good performance while also being economical and durable. Note that non-metallic (ie: PVC) divider partitions commonly used within wiring duct channels are similar in form to a noise barrier yet offer no protection against electrical noise. These dividers are intended for separation and increasing wire insulating factors but will provide no noise reduction or protection.

Shielding performance is also strongly linked to proper installation to achieve a low impedance (resistance) path to the sub-panel as part of the ground plane. Installation screws alone cannot create this low impedance path; to be effective a substantial area of metal to metal contact to the sub-panel must be made at each end of the barrier. Use of conductive galvanised sub-panels aids in making an electrical connection easily and reliably, versus painted panels which require paint removal for metal contact.

To ensure the low impedance path is maintained, bare metal surfaces should also be protected at the connection point with an anti-oxidising paste that does not affect conductivity.

September 2012 | industrial automation asia 39

software & Networks

Industrial Network Planning For Control Panels Requires More Thought Today Than In The Past.

Considerations When Implementing The Ethernet Layer Industrial network planning for control panels requires more thought today than in the past. With increase of industrial networking applications, two special considerations are warranted to maximum protection from noise in a control panel: • Panel space and cable management • Ethernet media and connectivity selection Space For Ethernet Switch, Patching, And Slack Management Proper space allocation provides important benefits for noise immunity for the switch as well as for the cabling. The cabling needs to be routed away from noise sources as well as needs to follow recommended bend radius control. For fibre, provide panel space for installing fibre patching with slack management. For both fibre and copper cables that need to leave panel, it is recommended to install patching so that the link can be tested.

Many cabinets can accommodate a side panel which can provide adequate spacing for a well executed industrial networking layer. Use of wire management products that maximise use of panel corners can provide additional back panel or side panel space as well as improve wire management and cable segregation.

Media And Connector Selection For Noise Mitigation Unshielded Twisted Pair (UTP) cable systems that have superior performance margins can be safely used in many automation systems if risks are understood and installation best practices are observed. Installation of copper Ethernet cabling near control panel noise sources increases risk potential for common mode noise coupling that can result in bit errors and delays.

Common-mode noise is the voltage that can develop on the entire LAN channel with respect to ground. Since Ethernet cabling system uses differential mode signaling, the voltage difference within the two wires in a twisted pair defines the signal so common mode noise should be subtracted out and not cause a problem.

The electrical balance of twisted pair cables and RJ45 connectors is key to preventing common mode noise from being converted to differential mode noise 40 industrial automation asia | September 2012

that corrupts communication. If the balance is perfect, then the differential mode measurements will be equal on both conductors of the twisted pair and thereby cancel out imposed noise. Not all manufacturers design their connectors for optimised balance so it is important to review this critical specification when choosing a connector as well as patch cable vendor.

Templates And Design Tools Reference designs, design tools and manufacturing product drawings (with some available in 3D formats) can greatly aid the control panel designer to conform to best practices to achieve desired system life cycle cost savings. Guidance tools provide control vendor recommendations for critical bonding and grounding to mitigate noise across the system. These reference designs detail how to lay out clean and dirty wire ways in the control panel to avoid noise coupling by providing recommended spacing between different classes of conductors.

Reference designs for industrial networking layer practice in control panels are also available to provide examples of best practice recommendations for an industrial Ethernet layer designed for performance, testability, reliability and maintainability. There are also recommendations for shielded cable practice as well as filter location and wiring guidance.

Conclusion Electrical noise is one of the core issues affecting the performance and reliability of industrial control systems and the real-time information they provide.

The noise emitted from sources such as PWM drives, power supplies, and inductive load switching can adversely affect system efficiency and uptime by interfering with analogue signals, industrial network transmissions, and PLC programs. To effectively mitigate noise in control panel environments, enterprises should: • Follow a multi-layered approach for grounding and bonding, segregation, shielding and filtering.

• Make special considerations for Industrial Ethernet including proper space and cable management, media and connectivity selection, and design for testability and maintainability.

• Utilise available reference designs and CAD design tools to improve consistency and efficiency of designs.

The use of these tools and methods provides a consistent defense to minimise downtime, quality problems, and erroneous communication due to noise without a significant cost increase to the panel designer and builder.

ENQUIRY NO. 6401

ENQUIRY NO. 479

instrumentation & Measurement

Integrated Solutions For Motion Sensing In Handheld Devices Implementing new gyroscope designs is taking shape and enabling more precise and cheaper solutions for motion control. By Dr Farrokh Ayazi, founder and CTO, Qualtré David Ritter, Phoenix, Arizona, US

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he motion and position of an object (eg: a handheld device) in space can be accurately mapped through the use of an Inertial Measurement Unit (IMU), which comprises of a three-axis accelerometer and a three-axis g y ro s c o p e . A c c e l e ro m e t e r s measure linear motion along the x, y, and z axes (axial acceleration), while gyroscopes measure rotation (angular velocity) around the x, y, and z axes. IMUs are being deployed in a myriad of consumer, automotive and industrial applications such as gaming, image stabilisation in cameras, user interfaces, navigation, electronic stability control in cars, and robotics.

Tr i - a x i a l s i l i c o n m i c r o accelerometers are now widely available in small form factors and at low cost. To leverage the full benefits of an IMU is these applications, a high-performance cost-effective tri-axial silicon microgyroscope is needed; preferably a gyroscope manufactured in a process compatible with the micro-accelerometer to allow subsequent integration.

High Frequency ModeMatched Gyros Today, commercially available 42 industrial automation asia | September 2012

MEMS gyroscopes use moving masses vibrating at low frequency range of 5-50kHz. This makes them susceptible to linear acceleration, acoustic energy from audio sources, and temperature fluctuations.

T h e c o m p a n y, Q u a l t r é , had been developing a new class of solid-state stationary gyroscopes that operates in the megahertz frequency range ( 1 - 1 0 M H z ) , s e v e r a l o rd e r s of magnitude higher than the existing technology. By using B u l k A c o u s t i c Wa v e ( B AW ) resonance in silicon, a solid-state disk gyro can achieve very high Q factors (Q factor is a measure of mechanical signal amplification) greater than 10,000.

The gyro uses two degenerate resonance modes of a disk with identical frequencies, a concept known as mode-matching, to achieve Q-times higher rotation sensitivity compared to moving mass architectures that use a s i n g l e re s o n a n c e m o d e .

Furthermore, a large bandwidth of a few 100Hz is attainable albeit the high Q resonance due to megahertz operation of the high frequency gyro. This allows for dramatic size reduction of the

gyro and manufacturing process without high vacuum.

Scalable High Aspect Ratio Fabrication Platform Implementing solid-state disk gyroscope designs requires a fabrication platform that allows the capacitive air-gaps in both lateral and vertical directions to scale down to nanometer range without requiring expensive nano-lithography.

The High Aspect-Ratio Combined Poly and SingleCrystal Silicon (HARPSS) process is capable of producing tens of microns thick, electrically isolated, poly and single-cr ystalline silicon microstructures with selfaligned nano-gaps. Such highaspect-ratio nano-gaps increase the efficiency of capacitive t r a n s d u c t i o n s u b s t a n t i a l l y, and enable an effective highfrequency interface to vibrating silicon microstructures. This structure produces the highest signal to noise ratios in capacitive MEMS devices.

The fabrication platform can be extended for future applications.

To this end, 150MHz single crystal silicon resonators with 80nm airgaps and a record high Q of

Benefits Of This New Class Of Gyroscopes With the rapid adoption of personal navigation applications, inertial sensors are challenged in differentiating between actual movement and environmental e f f e c t s . W h e t h e r t h e y a re temperature, shock or vibration induced, sensors can incorrectly translate these environmental effects into a motion signal. As such a device with high immunity to these environmental effects can significantly improve the performance of personal navigation apps.

Small form-factor solid-state high frequency sensor structures provide this high mechanical/ environmental robustness. Their structures are immune to the effects of temperature change, mechanical shock/vibration and environmental mechanical stresses providing a more reliable and accurate rotation sensing solution. Moreover, the company’s high-frequency capacitive sensors provide a high and stable Q. Roadmap To Integration The company is leveraging the HARPSS technology platform to enable integration of highperformance tri-axial microgyroscopes with tri-axial microaccelerometers on a common substrate to construct the best ‘performance-size-cost’ IMU. Particularly in consumer products where the demands for low power, small size and low cost, will drive the integration of these two types of sensors.

Looking down the road, gyroscopes will integrate with a c c e l e ro m e t e r s a n d o t h e r sensors (magnetometers and pressure sensors) to provide sensing solutions for a wide variety of applications.

Summary The BAW gyroscope design enabled by the HARPSS manufacturing process will deliver multi-axis gyroscopes offering wider dynamic range with high sensitivity, immunity to the effects of the temperature change, mechanical

shock/vibration, and low power consumption. It provides a platform for higher integration, reducing size, cost and system complexity in handheld motion sensing applications.

ENQUIRY NO. 6501

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ENQUIRY NO. 481

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13/02/2012 19:25 13/02/2012 19:25

September 2012 | industrial automation asia 43

instrumentation & Measurement

Control Of Motorised Wheelchair IAA spoke with LifeLine’s MD Michael Pang, on their innovation in the motorised wheelchair market, turning teeth clenching into motorised movement. By Mark Johnston IAA: Tell me about your company and what you have developed?

Michael Pang (MP): I have been in this business for the last 38 years and for this company, lifeline, that I am now the MD. This company is 21 years old, and we actually started of as a collaboration with one of Singapore’s higher learning institutions called Singapore Polytechnic.

They developed a controller for wheelchairs, we knew that for any motorised wheelchair it is the controller that controls the entire chair, it was pretty costly at that time. So, the government got this institution to develop this and a prototype was made and they commericised it so they invited a medical device company and Lifeline was selected to help them market this product.

We bought the intellectual property, and we pay a licence fee, we have enhanced it and made it ready for commercial use.

We are now able to lower the price of the motorised wheelchair.

Wheelchairs coming in from China are sold in Singapore at S$2,700 (US$2,164), we are selling a motorised wheelchair at S$1,800, so we managed to bring down the 44  industrial automation asia | September 2012

cost by S$900 because we have the proprietary rights.

Three years ago, Singapore Polytechnic developed a bluetooth controller, most controllers are wired. We realised that people may need wireless because everything is wireless today, so we developed this wireless bluetooth from three years ago and the purpose of this is to help people with, for example, muscle dystrophy, with restrictive movement. Some of them even sit on the chair and they can not move their hand to the control.

In 2011 we met this South Korean company at a show, it looked like he was controlling a jet, we thought it looked interesting.

It is good for quadriplegic, people with loss of control of upper and lower limbs. We asked them if they could integrate our controller with their invention. They asked us to send them our controller, which we did. They made some changes and so now it is compatible. We suggested we work together and that is why we will be attending the Medical Manufacturing Asia, show in Singapore.

So, this technology we are using is a Korean technology and the controller is a Singaporean technology. So it is a combined effort.

IAA: Were you pleased with the outcome of this product?

MP: Our aim was to bring down the price, and owning the intellectual property allows us to do that. The chin controller is very popular where they have a cup on the chin that can move the chair forward and back. The other one is the sip and puff where you have a tube that goes inside the mouth

where they blow to move the chair forward and sip to move the chair back. They are very expensive, about S$30,000, so we thought if we would give them another controller, another alternative to control the chair, using the teeth.

Because when you bite your teeth there is a muscle at your temple, which creates movement so we use the headband with a sensor that captures the bio-data. The EMG data is emitted when you have muscle movement and then it is transmitted to the monitor and then sends signals to the motor which moves the chair.

I was pleased with with results because I was able to bring the price down and offer a more economical solution. We do not sell one every

Michael Pang

day, but the main point is that when someone needs one, it is available and affordable.

we have developed. For other motorised wheelchairs we act as a distributor only.

IAA: When is this product available on the market?

MP: The product is currently available and we have sold it in Hong Kong, South Korea, and we are using Medical Manufacturing Asia as a platform to showcase our product to the region, we have also sold to Malaysia and Indonesia.

IAA: Are you intending to expand your own product range and go into new areas?

MP: Of course, we are always innovating, and looking for new

IAA: Where are your offices?

MP: We have offices in Singapore, Malaysia, and we have an office in Perth, Australia, and in Indonesia, Maymir, but our offices and mainly in Singapore and Malaysia.

products. As long as it is elderly care, and rehabilitation, we are interested. We have other products for cancer, respiratory, childrens equipment, emergency supplies, and so on. So the products that we are interested in are all here.

ENQUIRY NO. 6502

Bluetooth® Enabled Clamp On Earth Tester Report Generation

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IAA: What other products do you have?

MP: Well this product we are demonstrating is our main feature, it is our own development, but of course we have other chairs that we also motorise.

IAA: Who would be you main competitors for a technology like this?

MP: There is no one doing this in the world, but for our other motorised chair, our competitors are mostly US manufacturers. We decided not to invest so much energy in competing head on with these big manufacturers, but instead came up with something new, at a cheaper cost. The motorised wheelchair that can be controlled by clenching the teeth is our own product that

2

Automatic Report Generation on your Android™ phone

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The basic model FT6380 comes with standard measurement functions, and the FT6381 with Bluetooth data transfer capabilities, which allows auto report generation when used together with AndroidTM phones.

HIOKI Singapore Pte Ltd Tel: +65 6634 7677 ■ Fax: +65 6634 7477 Email: info@hioki.com.sg ■ Website: www.hioki.com

Report includes the Measurement Value, Date and Time, Map with GPS information and Pass/Fail information

3 Download data Via e-mail After making a report, you can see it on the Android™ phone or send the data to your PC at the office via e-mail

ENQUIRY NO. 477

IAA: Where do you sell most of your chairs?

MP: Our chairs are selling very well in Singapore, Malaysia, and Thailand. These are the three main countries because of the price.

Real time data transfer

September 2012 | industrial automation asia 45

energy

Edge and has used the software for a long time, so it became the software of Edison2. Though it actually was the software of two previous projects. which we worked on together. I was part of the Duran JE4, which was my friend Kevin Doran’s car that won the 24 hours of Daytona in 2004 and it was an entirely Solid Edge designed car. So was the Ford GT for the American LaMon series where he won third place, which was also a Solid Edge car.

Fostering Innovation IAA spoke with Oliver Kuttner, founder and CEO of Edison2, at Solid Edge University 2012.

Edison2 broke all land speed records with his new generation of electric car, with high efficiency and speed never before reached by an electric vehicle. By Mark Johnston IAA: Tell me about Edison2 and why you are at Solid Edge University 2012?

Oliver Kuttner (OK): It is racing that led to this Edison2 project, and basically I was trying to win a prize, especially this one as it was the biggest science prize on Earth. I believed from the beginning we could win, so I got some of my racing friends involved to design a new vehicle from the bottom up, and ultimately we won the x-prize.

I see this as the single biggest commercial opportunity on the planet because I believe there is a missed approach to transportation so I consider what we are doing as very important to the industry.

In the beginning most people did not take us seriously but now people are really starting to pay attention.

Sometimes I am stunned that people did not pay that much attention to us initially, but I am grateful for it now because I believe it has made us a stronger company.

The reason why we are at Solid Edge University 2012 is because before I even knew any of the people at Solid Edge my chief of design was a believer in Solid 46  industrial automation asia | September 2012

IAA: What is the target of your company?

OK: We have a unique architecture, which results in a very light car. Inside the car are a number of parts that are designed to be smaller than the average car. One such part is the suspension, which we were award a patent for. The suspension connects to a single point, and if you do that on all four sides, then your car structure only has four points.

The car is lighter because the structure itself is lighter. Parts like the transmission are smaller because the engine itself is smaller. Once we have a built car, it looks like any car would, the difference being that the whole car is lighter, which uses far less fuel than the average vehicle would. In the end, we wish to sell our knowledge to companies that want to mass produce our car.

Our company will not mass produce the car. We would like to sell it to someone in China, or India, and we have talked to people in both countries. Our car use simpler to make and it is lighter because of its structure. It is not like other cars which are more expensive to manufacture. Our car results in a cheaper process, so it produces much less pollution as a result.

The target of our company is to pass on our knowledge, and for other companies to mass produce and get a small fee for it. Our target is to sell millions of cars. We are not going to be a test lap that tries in five years to become a company that sells cars, that is not our target. If we sell a car it will come out from a big company with a big name and in big numbers and it still requires some work.

IAA: What is your approach to design?

OK: It is important to get every detail correct when designing a vehicle, especially if you want to compete for the x-prize, and win, so every detail matters.

We fight for very small amounts when it comes to details in designing our vehicles, because every little change has big consequences and this is where the Solid Edge program fits in, in helping us with detailed design. We are a small company, but we are very experienced. We have a desk of engineers, and fabricators, and machinists, all in the same room, talking to each other all the time.

IAA: What is the importance of Software in your design?

OK: Having a computer programme that is affordable but still of high quality is essential. We have to have people who speak to same language as us, but most of the time we are in separate locations. We have a lot of communication over the Internet. The software, Solid Edge, is the right mix, it is the right size that you can do perfect projects, but it is still normal enough that a smaller organisation, or individuals, can afford it. This is very important. So, it is not just about good software, but it also needs to fit into your business plan.

ENQUIRY NO. 6601

ENQUIRY NO. 444

IAA: What is the next stage for your company?

OK: We want to sell licences, we are at the point now where the car that we are currently designing, a company could take the design files from us and could modify and refine them to the buyers local needs and requirements, and mass produce the vehicle. We would like to sell those licences to multiple parties.

In particular, China, China is a perfect country

for our car, and a perfect country for some of our components. This is because there is a big pollution problem, and also, in my opinion, electric cars will not work until you do them the way we do them, because we can give you an electric car with a smaller battery that works over long distances. Our car is the modern cell phone for cars, and everyone else is running around with a big suitcase.

If you speak of an electric car in China, people will ask you where are you going to charge it. All those problems go away with our car. We have the enabling technology that makes electric cars actually possible. If you go to China, you will see a lot of electric bicycles, or mopeds. This is because you can charge such vehicles on a domestic outlet. With the currently generation of electric vehicles you cannot charge on a domestic outlet, you need a special outlet to charge the vehicle. We have that technology, the technology that would allow an electric car to be charged from a simple domestic outlet and last over long distances between charges. In China, in India, in small countries, our cars can be manufactured in low cost factories.

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17/05/2012 14:08:32

September 2012 | industrial automation asia  47

energy

G

reenlots is a company that launched in 2008, and is based in Singapore. It develops and markets a networked enabled charging system, which caters to different socket types, and various modes of charging. Intelligence has also been built in, designed to enable future applications in smart grid, user management, and vehicle telematics. According to the company this is achieved by developing an independent hardware and network operating system, products called ‘Greenlots Points’ and ‘Greenlots Sky’, and programming a set of data

acquisition algorithms from the Electric Vehicle Supply Equipment (EVSE) to the backend network.

IAA spoke with Oliver Risse, who co-established the company in Singapore in 2008. In establishing the company Mr Risse worked with the Economic Development Board (EDB) and explained to them the opportunities in electrification of transportation. Though at the time EVs were not widely available Mr Risse states.

“We talked about electrification, but it was always very clear it was not a car makers place here in Singapore,” commented Mr Risse.

commercialising this technology internationally,” stated Mr Risse.

“The company is a role model for the Singapore idea, locally developed, and internationally sold,” he added.

The government of Singapore is aiding the green technology project, not just in automotive, but in green building design, and developing a more sustainable, greener Singapore.

Digital Design In 2011 the company partnered with Autodesk, as part of its Clean Tech Partner Program, becoming

The Rising Electric Vehicle Interest in Electric Vehicles (EV) is gaining momentum around the world and most major car manufacturers are starting to produce electric cars. The increased interest and usage of EVs would have to be supported by intelligent EV charging networks, and a local company, Greenlots, is set to lead in global EV charging solutions. By Mark Johnston

It was obvious the US market was much better in terms of the automotive market, and more receptive to electrified vehicles.

The company seen an opportunity and set out to change that. They seen that what every car, bus, boat, bicycle, and so on, needs is an intelligent charging infrastructure that can operate on mass. So this is what the company developed, which, according to Mr Risse took the company one year to make a proof of concept.

“We have hardware and software working in real-time together, and since 2012 the company has been 48 industrial automation asia | September 2012

the first Singapore-based company to join the program. The program aims to supply digital prototyping software worth up to US$150,000 for only US$50 in a bid to help cleantech companies.

“Joining Autodesk’s Clean Tech Partner Program gives us access to professional design software that will help us compete globally.

We plan to use Autodesk Inventor software for stress testing our electric vehicle chargers. The chargers are used frequently throughout the day, and now we will be able to digitally simulate design improvements. As well,

the ‘Eco Materials Adviser’ in Inventor is going to help us select the most environmentally friendly materials,” stated Mr Risse Deciding on what materials are the most economically and to optimise your designs with the greenest footprint possible is a major aim of the company and the partnership with Autodesk aims to help achieve this.

“The company is very interested in the materials being used, and within the software there is a very interesting database for material science and streamlining your manufacturing process. The company can optimise the design phase, which is an important step,” said Mr Risse. “The company is interested in having a greener footprint, so the tools provided by Autodesk help,” he added.

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A Fast Industry The cleantech space in itself is a rapidly developing industry, with electromobility moving even faster. This is partly due to the support of the multi million dollar car industry, where millions of cars will be joining the roads in the years to come. “If you are not fast enough, you will not make it,” states Mr Risse.

The company is designing and building charging stations throughout Asia, Europe, and North America. Singapore is a small market so the company sees rapid growth in major markets throughout the world.

The company is expanding fast, and it must to stay competitive in this fast changing market, as Mr Risse emphasises: “To get a feeling for the industry, the

8/16/12

company along with all the other charging companies across the world have installed maybe 10,000 to 15,000 charging points globally. The market expectation in three to four years is going to be 1.5 to three million charging points. This is the pace the company will need to keep up with to stay competitive.”

In Conclusion The company is expanding in a fast moving industr y. With clear policy by governments to promote a greener society and concerns over cost of ownership for customers. The efficiency and convenience of the EV i s a n e n t i c i n g p ro p o s i t i o n to customers.

ENQUIRY NO. 6602

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ENQUIRY NO. 487

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September 2012 | industrial automation asia 49

sector spotlight

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he Changi Water Reclamation Plant (CWRP) Project was crowned the water project of the year at the Global Water Awards 2009 in Switzerland. The CWRP and Deep Tunnel Sewerage System in Singapore is supposed to collect, treat and purify every drop of used water produced by the city-state over the next 100 years.

This water project in Singapore represents in every aspect an unparalleled construction project.

It is planned to replace all existing local plants in Singapore.

Powering Singapore’s Water Super Highway Amounting to a project cost of S$3.65 billion (US$2.9 billion), the CWRP is a compact and closed sewage treatment plant built using the latest technology.

It is designed to treat 800,000 cubic metres of the 1.3 million cubic metres of water flowing through Singapore’s underground pipe daily wastewater daily and can be extended to a daily maximum capacity of 2,400,000 cubic metres.

The CWRP project was a challenge with regards to technological as well as logistical aspects and

ABB Service In Water ABB makes provision of electrical Balance Of Plant (eBOP) service to world’s largest covered wastewater treatment plant. By Joseph Quek, service sales & marketing manager, ABB

50 industrial automation asia | September 2012

ABB played a prominent role during its construction by providing extensive power solution packages, as well as automation products such as high-efficiency motors and medium-voltage drives that enable critical parts of the process to operate at the highest levels of energy efficiency and reliability.

In fact, throughout the entire water treatment process, at Changi, the company’s products and systems are powering, monitoring, measuring and speed-controlling crucial process equipment in the liquid and solids treatment modules, sludge drying systems, centrifuges and turbine generators, and effluent pumping station.

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FAULHABER SINGAPORE PTE LTD 25 International Business Park · #04-102 German Centre Singapore · 609916 Singapore info@faulhaber.com.sg · www.faulhaber.com ENQUIRY NO. 489

Water Service To CWRP The company has been supplying electrical, automation and service solutions to the global water industry for more than five decades. It has one of the largest installed bases in the global water industry, as well as market and technology leadership in power and automation technologies, unrivalled application know-how and process expertise in all application areas of the water cycle. These include water transfer systems, distribution and irrigation networks pumping stations, desalination plants, as well as urban and industrial wastewater treatment and re-use plants.

A key driver for the company is to deliver energy efficient and lifecycle cost optimised solutions.

And the company’s worldwide service capability and lifecycle management expertise enables plants to keep running optimally throughout their entire operational life.

After the Changi Water Reclamation Plant went into full operation in June 2009, the company overall contract sales coordinator from ABB Singapore Discrete Motion and Automation division has been following up with the customer and noticed that they had a demand for a complete service package.

The customer had contacted various departments for their service requirements. The company’s service team responded by collaborating across the divisions to create a single comprehensive service contract for the customer.

With its products, systems and services, the company follows through the whole lifecycle of Changi Water Reclamation Plant, from engineering to construction and eventually now, ser vice and maintenance. It supports CWRP in identifying the best solutions for their specific needs, including maintenance and asset optimisation.

It has been awarded a service contract from the Public Utilities Board, valued at approximately S$2.1 million. The three-year service and maintenance

∅ 22 mm with integrated Motion Controller

September 2012 | industrial automation asia 51

sector spotlight

ABB equipment at Changi Water Reclamation Plant

The Changi Water Reclamation Plant (CWRP) Project was crowned the water project of the year at the Global Water Awards 2009. contract for the electrical Balance Of Plant (eBOP) will help ensure reliable and efficient operations of CWRP. Among the service package includes the vital maintenance of critical equipments such as 21 units of medium-voltage high-efficiency motors and water-cooled medium-voltage drives that power and control the huge pumps at exceptional levels of energy efficiency.

The service contract is a three years full service contract signed in August 2010. ABB equipments covered under this contract included high voltage distribution boards and transformers, mediumvoltage switchgears, medium-voltage motors, medium-voltage drives, both low and medium voltage transformers, low voltage switchboard, low 52  industrial automation asia | September 2012

voltage switchgear, low voltage motors and low voltage drives.

Under this service contract, the company provides 24/7 certified standby engineers, and response to site within four hours for their critical equipments. Suitcase support is within the provision as well. A key engineer is assigned to support CWRP and coordinate internally various service groups to establish a single contact point. Through this contract, it helps CWRP to plan and execute annually or biannually the maintenance service necessary to ensure most reliable and energy efficient operations.

Other value-added services of this full service contract include providing parts online access, maintaining the history of the failure log book,

CWRP plans to replace all existing local plants in Singapore.

providing refreshment training for basic training and operation of the company’s equipment. With the Logistic Center Asia (LCA) located in Singapore, fast response on spare parts is available. Last but not least, also viewed very importantly by CWRP is redlion_ad.pdf

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15/08/2012

the ability of ABB to provide factory certified and well established drive service workshop and motor service workshop services in Singapore.

Key Success Factors In Service The company is able to present to the customer as one approach with good coordination with various internal service groups. Customer expectations are met and guaranteed through service contracts.

The company helps CWRP plan and maintain their equipment by providing the necessary services to their equipments based on factory recommendations.

The company helps customer to minimise their spare parts inventory. It proves a peace of mind given to CWRP maintenance team as the company will always be there to support and resolve any of their issues in all the critical equipments.

CWRP has recognised how the company’s service can help increase the reliability and efficiency of their operations. The customer will now have easy access to its sales and service engineers via a clear and simple contact chart.

ENQUIRY NO. 6701

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September 2012 | industrial automation asia 53

Quest For Clean Water

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he Organisation for Economic Co-operation and Development (OECD) has estimated that close to 50 percent of the world’s population will be living under severe water stress by 2030. This is likely to happen if there are no newer policies put in place to address the problem.

The majority who are affected will be those living in developing countries such as Brazil, Russia, India and China.

Problem Prevention In Asia, countries can begin to take steps to avert the impending problem by developing their 54  industrial automation asia | September 2012

In the face of acute shortages in the near future, decision makers need to adopt reliable and sustainable technology to ensure uninterrupted access to water sources. By Lau Wee Pheng, product manager, and Sim Jee Kar, senior project engineer, Mitsubishi Electric Asia

respective water management capabilities. This can be achieved by building up a diversified supply of water sources, which could include local catchments, imported water, recycled water and desalinated water.

A particular public utilities company in Southeast Asia for example, faces various challenges.

Besides having to identify various sources of water, another challenge is in maintaining its current automation system to ensure that it can support the country’s water needs for the next few decades.

Although newer technologies are constantly being developed,

Afonso Lima, Sao Paulo, Brazil

sector spotlight

selecting a technology that is not outdated but yet to be proven, may sometimes be required.

Technology needs to be applied to different aspects of water conservation such as transporting water from catchment areas and then processing it to a quality that is needed for human consumption.

In the area of wastewater treatment, technology should be able to aid regulatory requirements, and fulfil social and environmental responsibilities to ensure that quality standards are reached.

Wastewater that comes as a byproduct of industrial, commercial and residential applications,

need to be carefully processed for reuse or to be returned to the environment.

Such water management solutions mean multi-million dollar investments in infrastructure and hardware. Decision makers have to therefore exercise prudence in selecting the right technologies to lower operational costs, raise efficiency and increase system availability.

to Information Technology (IT) systems to provide higher-level reporting, monitoring and control.

Safe To Drink The potable water production process starts at the pump station where raw water from various man-made (eg: reservoirs) and

natural sources (eg: rivers, lakes) is transported to the treatment plant. Pumping applications that require up to 630 kW are supported by the FR-F700 family of Inverters, allowing energy savings of up to 60 percent to be achieved via the Optimum Excitation Control (OEC) technology.

Human Consumption In the production of potable water, the iQ PlantSuite provides the necessary software tools to enable the rapid deployment of projects. The iQ Works integrated development environment takes care of each phase in a project.

These are:

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Graphical System Designs Programming Tools Deployment Debugging Operation Maintenance

By ensuring that errors are reduced through testing and simulation for integrated Programmable Logic Controllers (PLC), Human-Machine Interfaces (HMI) and Inverter or Drive Systems, system optimisation can be accomplished within shorter timeframes and at a lower price tag.

The platform is capable of interfacing with almost all open networking systems on the market. Riding on advanced distributed system technology, these solutions ensure reliability and availability while keeping costs down — compared to systems that run on conventional and proprietary systems.

Automation components including PLCs, HMIs and Inverters, can be networked in a distributed system environment.

Controllers can also be connected

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September 2012 | industrial automation asia 55

sector spotlight

like CC-Link IE enables each local metering station to communicate effectively with the central controller system.

Portable water technologies

Wastewater treatment facility

After initial screening, the flocculation process removes suspended solids and clarifies murkiness and discoloration in the water. As precision is required for controlling the amount of flocculants, precision in technology is required to ensure that the correct tolerances are maintained in the entire process.

For added reliability, controllers with dual redundant architecture can be deployed to minimise system downtime.

The next stage is filtration a n d s e d i m e n t a t i o n , w h e re pumps are used to channel water through filtration systems.

Inverters ensure that energy consumption is minimised.

It is also possible to integrate mechanical systems — utilised for removing sedimentation sludge — into the solution. Pump control for the back-flushing 56 industrial automation asia | September 2012

of the filters can also be put in place. For such processes, PLCs can be used both for the central control station as well as for local control functions.

The final stage which ensures that the processed water is fit for consumption is the disinfecting process. It is required to ensure that the water is of a sufficiently good quality for consumer use.

Being a mission-critical process, this process requires failsafe redundancy mechanisms to be put in place.

A controller system that plays this role is required to provide the reliability that is required. Using data that is generated from local stations, real-time processing and centralised logging are performed.

This allows the required tolerances to be accurately maintained on a perpetual basis.

Redundant network architecture

Industrial Treatment Technology Besides personal consumption, water is also used for industrial processes such as processing, heating and washing. After it has performed its required purpose, this wastewater needs to be collected and treated before it can be safely reused. It is important that the water is properly processed to prevent contamination, since poor quality water can create defects in products. At a macro level, discharging water that has been improperly treated can cause pollution and could have long-lasting effects on the environment.

Furthermore, as regulatory measures in Asian countries become increasingly stringent, companies need to comply with the requirements of their respective local governments for wastewater treatment.

Wa s t e w a t e r t r e a t m e n t involves four phases. The first is the mechanical screening, where raked bar screens remove particles from the water. After these solids have been removed via screw conveyors, the water is directed through an aerated sand channel — this allows heavier substances to be sifted out and disposed. The lighter particles are skimmed off from the primary settling tanks and taken out.

The remaining wastewater is then pumped out to stations for biological treatment.

PLC controllers are used to monitor and control these processes while networked f re q u e n c y i n v e r t e r s d r i v e aeration pumps. At the same time, integrated diagnostics systems allow engineers to schedule maintenance jobs ahead of time.

Technological Efficiency Given the various processes that need to be carried out,

plant owners and managers need to be aware of the various technologies that are available to treat industrial wastewater effectively and efficiently.

This comes in the form of the iQ PlantSuite, which makes up the core of major wastewater treatment plants that run on networked central monitoring and distributed control systems.

Pump systems are necessary for wastewater treatment systems.

As these pumps typically consume large amounts of energy, there is a need to adopt energy efficient technology to move wastewater with minimal energy consumption.

Frequency Inverters are used to ensure that pump systems per form at their optimum levels, and are recommended for deployment in unattended and remote stations. With the help of networking tools, even installations that are located in far-flung locations can be reliably managed and monitored.

Operator support is offered in the form of both HMI panels and a centralised process visualisation system. Via the network, the same information can be accessed by both local HMI panels and the control station. By leveraging on these available tools, engineers can gain timely access to information on the entire operation. In the event that process errors occur, engineers can swiftly implement solutions to remedy the situation.

Given the challenges in gaining access to suitable water for drinking and industrial purposes, stakeholders need to understand the technologies that are available, and to make wise investment decisions that will be beneficial for current and future generations.

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ENQUIRY NO. 493

Stage two involves oxygenating the water. This is where agitators mix biomass with wastewater in the activated sludge tanks. An aeration system is used to oxygenate the water — which encourages bacteria to consume the biodegradable organic substances in the wastewater. PLCs control the processes while frequency inverters are used to power the inlet and outlet pumps. These technologies enable engineers to maintain the correct parameters, in order to create the optimum environment for the bacteria to multiply.

The next stage, ie: secondary treatment, involves the removal of nitrogen and phosphorusbased nutrients from the water.

Other filtration processes are also performed to remove remaining pollutants that could adversely affect the quality of the water. These processes are managed by the iQ PlantSuite control system that comes with a dual redundant architecture, that helps to negate the risk of failures occurring.

Stage four involves sludge processing; the sludge is first separated from the purified wastewater. A portion of the sludge is pumped off while the rest undergoes further processing. The F700 Inverter is suited to power pumps that are required for maintaining flow rates, rotating sprinkler arms as well as sprinkler pumps for trickle filter systems.

The next step is to collect the sludge in separation stations, and to remove and pump the water back into the process.

The concentrated sludge is transferred to anaerobic tanks where it is further decomposed.

September 2012 | industrial automation asia 57

features

The Forklift Of The Future:

Integrating Voice, And Barcoding Technologies Technology is playing an increasingly prominent role in the life of manufacturers, enabling more efficient processes and cost savings. By Mike Muller, VP and GM, Intermec (Asia Pacific)

A

s i a n m a n u f a c t u re r s a re constantly on the lookout for innovative supply chain processes and technologies. Of particular interest to manufacturers are advances which can improve production efficiency and the accuracy of their warehouse operations.

Relying solely on traditional manual processes to track and trace inventory, parts and goods through the manufacturing supply chain is no longer ‘best practice’, nor is it even recommended practice.

Where tracking technologies were once used in isolation in the warehouse and manufacturing environments, solution providers tended to develop one of these technologies and promoted it over other alternatives. These days, advances in voice recognition, barcode and RFID technologies, along with forklift innovations mean these disparate technologies are now able to work as one 58 industrial automation asia | September 2012

holistic solution driving change in the modern manufacturing environment.

For manufacturers thinking about integrating vehicle-mount technologies, it is important to understand how these solutions w o r k t o g e t h e r t o i m p ro v e efficiency and accuracy within a manufacturing environment.

The Differences Between Forklift-Mounted Voice And Scanning Terminals Voice systems are used by hundreds of thousands of manufacturers in warehouses worldwide, with barcode scanning systems even more widely deployed. Compared to manual paper-based processes, these technologies provide vast productivity and accuracy improvements for manufactures.

These two technologies are used in ver y different ways within the warehouse, with each having its own distinctive

strengths and weaknesses.

Voice Picking: Picking is the most common application of voice technology in the warehouse. In a typical voice pick, a voice terminal (worn on the order selector’s belt) directs the wearer to a pick location through the headset. When the user arrives at the pick destination they confirm their destination through the headset and are then directed by the warehouse management system to pick the required amount of items.

T h i s p i c k i n g p ro c e s s i s accomplished without any visual prompts or key data entry (so no computer screen, keyboard or other input device is needed).

The voice interface also makes picking operations extremely accurate, with voice users reporting picking accuracy rates upwards of 99 per cent.

Improved picking accuracy is a key component of the voice technology value proposition.

forklift. Screens can display more extensive instructions, plus images and even video, to provide operators with a higher level of support than a pure voice solution. This makes barcode systems popular for a number of situations.

How Are These Integrations Incorporated Into The Forklift And Picking Process Having identified the value of multi-technology systems, the final barrier to implementation is determining the best ways manufacturers can take advantage of the potential benefits.

Cost-effective terminals that support voice, barcode, RFID and other technologies are now becoming more widely available.

The relative availability of these technologies is indicative of the industry’s desire to integrate them in warehouses.

The advantage of these multifunction terminals is that they eliminate the performance trade-offs that are required when a single input technology is used for all warehouse operations. In a warehouse, where fundamental repetitive tasks are performed thousands of times each day, using the most efficient technology to make a small improvement to a process can produce significant productivity gains.

With an integrated solution, manufacturers have the option to use processes that are voice only, voice-and-scan, or voice-scanand-screen. This flexibility helps maximise labour productivity and efficiency. Different people work more effectively with different technologies and multifunctional terminals offer manufacturers the best chance of maximising their value and ROI. ENQUIRY NO. 6801

ENQUIRY NO. 476

Manufacturers that use voice technology in their distribution centres are 1.6 times more likely than non-voice users to allow dynamic task interleaving, such as switching employees from picking to replenishment. Not coincidentally, voice users were also found to be 1.7 times more likely to eliminate idle resources or reduce staff.

Voice is most effective for highly repetitive tasks with few variations in the process. Operations that give workers flexibility for their pick routines (such as the ability to pick items out of the prescribed order to avoid congestion in an aisle) and those that involve frequent exceptions may be better served by utilising another input technology, like scan picking.

Scan Picking: A typical forklift pick using a scan-based process involves the driver interacting with a forklift mounted screen, which directs them to and from the pick destination. The screen will inform the driver of the amount of items that need picking, the items are then scanned as they are picked to record and confirm the correct amount has been collected.

The pick transaction is one of the most commonly used processes in warehouse management. Millions of items are scanned after they are picked each day. The advantage of this process is that barcode scanning is extremely accurate and requires much less time than recording picked items with a keypad or paper form.

Compared to voice, scan-based picking requires a few extra process steps that can limit productivity when repeated over thousands of picks. Also, because voice keeps the user’s eyes and hands free, it provides a major safety advantage for forklift operators over screenbased systems.

However, there are advantages to having a screen, which is needed for scan picking, on a

September 2012 | industrial automation asia  59

EVENT PREVIEW

OSEA 2012

The 19th edition of Offshore South East Asia (OSEA) will open its doors from November 2730, 2012 at a new location, the Marina Bay Sands in Singapore.

The show expects growth of 15 percent compared to the 2010 edition. More than 25,000 trade attendees will have opportunities to interact with 1,500 international companies across 31,750 square metres of exhibition space.

Several National Oil Companies (NOCs) will take part in the show, and the event will also boast an increase in the number of country pavilions from 10 in the previous edition to 13 this year, from Australia, China, Denmark, Finland, France, Germany, Italy, Netherlands, Norway, Russia, Singapore, UK and US. “As the demand for crude oil and natural gas intensifies, the world will see an increase in exploration and development activities,” says Stephen Tan, CEO, Singapore Exhibition Services (SES). “Since its inception in 1976, OSEA has steadily grown from edition to edition to become the industry’s sourcing ground and business networking platform for the global oil and gas industry in Asia today.

Relevance is crucial in today’s 60 industrial automation asia | September 2012

economic and business landscapes, and with this in mind, the event is poised to shine brighter than ever as it readies to unveil the latest products, services, technology and knowledge that are vital for greater growth,” he added.

Also participating in OSEA for the first time are individual exhibitors EMAS AMC, Franklin Offshore International, M-I Swaco, Marco Polo Marine, Remazel Engineering SPA and more. They will be joining returning exhibitors who will be back again this year to connect with existing partners and build new business relationships.

Commercial Challenges, Technological Innovations Held concurrently with the exhibition, OSEA 2012 International Conference, a platform for leaders and experts in the oil and gas industry, will return with an exciting line up of conference tracks. In 2010, the four day conference was attended by over 200 speakers and delegates from 30 countries/regions.

R e f re s h e d f o r 2 0 1 2 , t h e conference is structured into four tracks that delve into important topics such as the global outlook and its impact on Asia,

commercial trends and challenges, revolutionar y technological innovations in offshore development & production, offshore safety management, natural gas & Liquid Natural Gas (LNG) developments, as well as a technical programme focusing on facilities engineering, enhancing production operations, and energy management and sustainability.

T h i s y e a r, l e a d e r s a n d practitioners of many of the world’s leading companies from the oil and gas industry will be speaking at the OSEA 2012 International Conference. Confirmed speakers include Keith Lewis from the Subsea Well Response Project (SWRP) — a non-profit joint initiative of nine major oil and gas companies, BG Group, BP, Chevron, ConocoPhillips, ExxonMobil, Petrobras, Shell, Statoil and Total.

Thomas Jamowski of Herrenknecht Vertical and Saleh Al-Rasheedi of Kuwait Oil Company, amongst many others, will also be sharing their views with delegates from around the world.

November 27-30, 2012 Marina Bay Sands Singapore ENQUIRY NO. 6901

EVENT REVIEW

Solid Edge University

2012

Solid Edge University 2012 took place at Gaylord Opryland Resort & Convention Center, Nashville, Tennessee, US, between June 11 to 13, 2012. The event hosted many demonstrators and partners for the company’s Solid Edge software solutions. The event withnesses a preview of Solid Edge ST5, the company’s new generation of software.

STS has several advantage that were pointed out at the many seminars and during the keynote address that the company held each morning. Some of these advances include core design capabilities aimed at helping users develop better products faster.

The company also announced Solid Edge Mobile Viewer, a 3D viewer mobile device application designed for the iPad, which broadens access to design data to help companies enhance collaboration.

“The new features in Solid Edge ST5 are driven by our strong focus on our customers’ requirements.

By responding directly to their September 2012 | industrial automation asia 61

EVENT REVIEW

needs, we ensure each functional e n h a n c e m e n t d e l i v e r s re a l business value,” said Dan Staples, director of Solid Edge product development, Siemens PLM Software.

Synchronous Technology The company continues to use their synchronous technology in Solid Edge ST5, which uses the technology to provide enhanced support for multi-body modeling, which lets users import parts and assemblies from virtually any CAD system. The resulting imported geometry can be combined into a single part or multiple parts depending on manufacturing requirements.

“I am very impressed with what I have seen in Solid Edge ST5; especially the new multi-body design capability,” said Grant Holohan, mechanical engineer, Hatch, a global EPCM company specialising in designing largescale mining operations. “The new multi-body design capability gives us the freedom to design without worrying about individual parts unless needed. Using Solid Edge ST5 will dramatically increase the design productivity of our staff, saving a substantial amount of design time,” he added.

Simplify Drawing Documentation In many design and manufacturing companies, drawings are a key deliverable. Solid Edge enhancements continue to focus on drawing productivity to help lower shop floor errors.

Enhancements in Solid Edge ST5 include the ability to show an assembly in multiple positions within a drawing view, to automatically place parts lists across sheets, and easily align the position of dimensions. A new marquee feature is the ability to create nailboards of electrical wiring harnesses, complete with flattened and ‘bend’ views, drawing views of connectors, and connector and conductor tables for creating complete manufacturing documentation.

Thermal Analysis For SteadyState Simulations Engineers often need to simulate both thermal and mechanical systems where a part may have to undergo both stress and a thermal load. And when issues are encountered, they require a fast, easy approach to making changes that improve design quality.

There is now steady-state thermal simulation and when coupled with

synchronous technology users can test more alternatives in less time, so designers can reduce the need to build and test physical prototypes.

Mobile Viewer App Users across a company now have the ability to view 3D parts and assemblies created with Solid Edge using the new free Solid Edge Mobile Viewer app on an iPad. The app includes the ability to rotate, pan, zoom, show and hide parts, create and email images.

Solid Edge Mobile Viewer allows individuals outside of the traditional design and engineering departments to view design data, enabling faster, more convenient design reviews, customer presentations, or general model inspection.

In Conclusion The event overall was a success with many customers showing interest in the new additions included in ST5 and involving themselves in the many seminars and demonstrations throughout the event.

Gaylord Opryland Resort & Convention Center Nashville, US June 11-13, 2012 ENQUIRY NO. 6902

Executive Talk IAA: What is your role at Siemens PLM? Karsten Newbury (KN): My name is Carson Newbury, senior VP, mainstream engineering, Siemens PLM. Solid edge is one of our main products, I have personally been with Siemens for 16 years.

Karsten Newbury

Bill McClure

62 industrial automation asia | September 2012

Go Say Tiam

Bill McClure (BC): I started in this industry with Intergraph back in 1985, and I basically ended up running the mechanical division at Intergraph and was part of the team that made the decision to move the company to Windows and developed a

“The new multi-body design capability gives us the freedom to design without worrying about individual parts unless needed.” - Grant Holohan, Hatch

KN: I think there is a broad level of improvement in many areas, and also to answer your previous question with ST4, what we really found is that a year ago during the release of ST4 there was a lot of excitement around synchronise technology with the our traditional users that use history based Solid Edge modelling, and I think that is carrying forward, as we are expanding synchronise technology. It really depends on what the users preferences are.

Windows based CAD system which became Solid Edge. In 2001, when we acquired STRC, I took over responsibility for all the mechanical CAD products, which included Solid Edge. I was part of the team that formed the mainstream engineering organisation.

IAA: What would your top industries be?

KN: Our top industries would be machinery, hitech, customer products, and speciality vehicles.

ENQUIRY NO. 6903

Go Say Tiam (GST): My name is Say Tiam Go, I am the VP for mainstream engineering volocity business in Asia Pacific. I have been in the software industry for 20 years, but the last 10 years have been in the PLM industry. I have been with UGS Siemens for the last seven years.

IAA: What one feature in ST5 would your customer find most beneficial for them?

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IAA: What feedback did you get with ST4, and what improvements have you made to ST5 that is based on feedback you got from the previous edition?

BC: The key things that we are finding in ST5 is that we focused on the core synchronise technology and we continue to focus on the mechanical design core and continue with performance and the use cases it can handle. One of the things that we did was that we enabled multi body modelling with ST5 in the synchronise environment. The second major area that we did in ST5 is the terminal analysis and the simulation. We also did a lot of work in designing and drafting, which may be a boring topic to talk about but it is a very important topic for our customers. We really feel like we have the best tool on the market for creating a drawing from a 3D model, and with each release we continue to add more functionality. Also, ST5 is where we decided to release Insight XT.

Asif Akbar, India

IAA: BC, are you one of the founding developers of Solid Edge?

BC: I was in the executive team at Intergraph in 1993 and said we are going to move everything to Windows. At that point we did not even have a name for a product yet.

IAA: Would this also hold true in Asia?

GST: In Asia, machinery would also be the largest customer base. Machinery is very broad based, so we would go after Semicon type machineries and for example in China, we have a lot of customers in elevators. The problem is how you classify that. We are also getting into customer products. The trend is basically similar to what you would see globally.

September 2012 | industrial automation asia 63

EVENT REVIEW

Honeywell Users Group (HUG) Symposium 2012 Honeywell showcased the latest advancements in process automation and controls that will help manufacturers in Asia Pacific sustain their performance and life cycles to maximise plant safety, reliability and efficiency.

Themed ‘Sustain.Ability’ the 2012 Honeywell Users Group (HUG) Asia-Pacific Symposium highlighted Honeywell’s newest products including the nextgeneration Experion Orion Process Knowledge System (PKS) and the new collaboration software Intuition Executive.

Honeywell User Group Asia-Pacific Symposium 64 industrial automation asia | September 2012

is the company’s largest customer gathering in the region, where more than 200 customers and partners attended over a four days period, from August 5-9, 2012 on the Gold Coast, Australia.

“Asia continues to exhibit growth as customers in the process automation industry for growth and development. However, with the economic turbulences, customers in the process industry are looking for technologies and solutions that help improve operations, better manage assets, drive efficiency and generate returns on investments,” said Jason Urso, CTO, Honeywell Process Solutions.

The Highlights At HUG Asia-Pacific Included: • Experion Orion PKS, Honeywell’s flagship offering.

This next generation system has undergone advancements that can help improve plant production by up to 13 percent, reduce operatorrelated safety incidents and lower the total of cost of ownership by up to 30 percent. The new Experion Orion PKS is the first industrial process system to use ‘Universal Channel Technology’ to remotely configure process and safety systems without the need for additional hardware.

• A first-hand look at Honeywell’s recently launched Intuition Executive collaboration software which allows manufacturers to analyse and visualise data across their entire enterprises to better respond to volatile energy costs, complex regulatory changes and real-world safety challenges.

• A live demonstration of a new 3D simulation solution Honeywell is developing that combines visualisation technology with its UniSim Design Operations simulation tool. The solution will provide a holistic virtual environment that plants can use to efficiently design, analyse and verify plant operations.

• The winner of the 2012 Asia Pacific UniSim Design Student Competition, Tuyen Dinh Quang of Hanoi University of Science and Technology, showcased the winning solution, designed to simulate the complex petroleum refinery process to help optimise production.

The HUG APAC 2012 program consisted of four days of customer-driven sessions and presentations, as well as demonstrations of the latest Honeywell

technologies designed for the process industries.

Industry-specific tracks included oil & gas, refining, chemicals, mining and pulp & paper, and covered topics such as plant modernisation, control system migration, oil & gas measurement and simulation.

August 5-9, 2012 Surfers Paradise Marriott Resort & Spa Gold Coast, Australia

ENQUIRY NO. 6904

ENQUIRY NO. 492

“At this year’s Honeywell Users Group Asia-Pacific Symposium, we are showing attendees how they can manage priorities to achieve and sustain good business performance,” added Mr Urso.

September 2012 | industrial automation asia 65

EVENT REVIEW

Executive Interview

IAA spoke with Joe Spirito, sales director (APAC), Honeywell Process Solutions on the company’s current investments and involvement in the Indonesian market.

IAA: What is Honeywell’s involvement in Indonesia?

Joe Spirito (JS): Honeywell as a corporation has made special investments in Southeast Asia, Vietnam and Indonesia are two high growth regions for us. What that means is basically Honeywell Corporate would invest in Indonesian Manufacturing, people, offices, and so on. So, I believe we are in the process of searching for and hopefully appointing a new Honeywell Corporate country manager for Indonesia to help drive the investment in there from a Honeywell Corporate level. That is the first thing.

So from a Honeywell Corporate level in Indonesia we have roughly 14,000 people, across all our businesses, in about eight locations, roughly. For Honeywell Process Solutions we have approximately 150 people in Indonesia, that is between engineering, sales, and services, and so on. Primarily our main base is the Jakarta area.

66 industrial automation asia | September 2012

IAA: Who would your big customers be in Indonesia?

JS: Pertamina would be one of our major customers in Indonesia, which we support everything from control system to safety system to advanced solutions, so advanced process control, Information systems. In fact with Pertamina, in the last 18 months we have opened a special training centre in Jakarta, because the company uses in a lot of their refineries, and UOP technology.

UOP is our sister company, so we developed a simulation package with UOP, so therefore the processes and the simulation are very close. We opened a training centre for the company, using UOP, and Honeywell simulation so they can train all their operators, and so on. That was a major effort on our part with Pertamina and UOP and it is quite a large facility.

IAA: What is your target market for Indonesia?

JS: Upstream and oil and gas, ever ything from terminals, refineries, pipelines, and obviously the Upstream. We say that is our target market but realistically the market is so big we cannot ignore it. We are also very strong in the mining area, and pulp and paper. So those would be the major markets we focus on for Indonesia. Pulp and paper is a very important market for us in Indonesia, we have a dedicated team for pulp and paper that works specifically in this space only, and not across other areas.

Normally our sales and execution teams would work across different markets but for pulp and paper they focus only on this.

ENQUIRY NO. 6905

Vietnamese Student Wins Asian-Pacific Competition Dinh Quang Tuyen, a chemical engineering student from the Hanoi University of Technology was announced as the winner of the 2012 Asia Pacific UniSim Design Student Challenge at the Honeywell Users Group (HUG) Asia-Pacific Symposium.

Mr Tuyen used the UniSim Design Suite to effectively simulate the most important conversion process used in petroleum refineries, called Fluidised Catalytic Cracking (FCC).

It is expected to help to maximise the gasoline yield produced. The simulation model was tested for accuracy by using crude oil from a Vietnamese refinery.

The student showcased his winning design to almost 200 industrial experts and manufacturing companies at the HUG Asia-Pacific symposium.

The company’s UniSim Design Challenge is an annual competition for university students held in conjunction with the symposium.

ENQUIRY NO. 6906

products & Services Aerotech: Non-Contact

Ametek: Non-Contact Linear

The ABL1500 direct-drive linear air-bearing stage from Aerotech meets the needs of scanning and inspection applications with fully active pre-load, stiffness and geometric characteristics.

Its positioning tolerances exceed the capability of conventional ball-screw and mechanical-bearing systems. The non-contact design allows years of maintenance-free operation.

The stages are appropriate for critical applications in any industry that requires smooth and accurate linear motion to manufacture, test or inspect a product. These include semiconductor, data storage, medical and genome devices and industries requiring cleanroom operation.

A non-contact Linear Displacement Transducer (LDT) from Ametek Automation and Process Technologies offers greater durability and consistency than traditional potentiometers.

The magnetostrictive technology of the Gemco 955 eBrik has no moving parts to wear out and does not exhibit problems common to linear potentiometers.

It is designed to provide accurate continuous position feedback when installed on automated factory and processing machinery. Industry applications include plastic injection moulding and extrusion equipment, tire and rubber and die casting among others.

The sensor offers field programmable zero and span settings, plus electronic diagnostic feedback transmitted through the analog output. It is accurate to ±0.03 percent of stroke with repeatability to 0.001 percent.

Direct-Drive Linear Air Bearing Stage

Enquiry no. 6907

Displacement Transducer

Enquiry no. 6909

Agilent: Dual Mobile

Denso: Robotic Arm

The Agilent 66309B offers features suited for testing wireless and battery powered devices. The products voltage transient response ensures maximum test-system throughput by minimising device shutdowns due to significant voltage drops in the test wiring. Built-in advanced measurement system to accurately measure battery current drains when the device operates in different modes.

An Agilent-developed feature that enables cellular telephone manufacturers to detect permanently and intermittently opensense wire connections. Plus two outputs for testing both the main battery power and the battery charger circuitry, allowing testing of phones and chargers with the same equipment, as such saving rack space and eliminating the need for two separate power supplies.

Denso has more than 60,000 of its robots installed across the globe, 16,000 of which are employed in its own manufacturing facilities.

Currently, using (ORiN) Open Resources Interfacing Network, the company’s robots can be controlled by C#, C++, VB. Using this strategy, the company helps to reduce the time requirement of programmers who are proficient in common language to design robotics systems. Its’ proprietary software WinCaps 3 is also available to conventional robotics programmers.

Communications DC Source

Enquiry no. 6908

Enquiry no. 6910 September 2012 | industrial automation asia 67

products & Services

Di-Soric: Dynamic Fork Light

Barriers

The OGUTID series of devices by Di-Soric is based on a dynamic working principle. This feature allows them to only detect rapid changes along the optical axis, while automatically disregarding slow changes that might be brought about by, for instance, the accumulation of dirt.

A highly effective auto teach procedure makes it easy to find the perfect setting. Another advantage is that the fork light barrier can be programmed to work with a wide range of settings from high resolution to insensitivity to dirt.

Typical applications for the OGUTID include: detection of oscillating filaments, injection monitoring for spray mists, detection of small parts in tubes, ejection control at punching machines, and standstill control in feeding units.

Enquiry no. 6911

Endress+Hauser: Pressure

Transmitter

Endress+Hauser introduces The Cerabar M PMC51 and PMP51 pressure transmitters, which are suitable for accurate absolute and gauge pressure measurements in gases, steams or liquids, and for level, volume or mass measurements in liquids. These products have been specifically designed to meet the needs of the food and beverage and life sciences industries.

The Cerabar M transmitters are available with ceramic or metal process isolating diaphragm seals which allow the sensors to work in temperatures up to 752 deg F (400 deg C) or pressures up to 6,000 psi. Outputs include 4-20mA, 4-20mA with HART, Profibus PA and Foundation Fieldbus.

Enquiry no. 6913

DMG/Mori Seiki: High-Speed

EOS: Laser-Sintering — The

The only thing the current machine has in common with its predecessor is its name because the Sprint 50 has been redesigned, a fact that is reflected in an increase in performance and flexibility. This has been achieved due to the integrated Twin concept and the cross traversable counter-spindle/tailstock combination.

In addition, the Sprint generation by DMG/Mori Seiki has a consistent modular design. As a result, an optimum machine configuration can be ordered for different requirement profiles.

The launch version of the turning machine with its two turrets and up to two Y-axes is just the start of the new era. It is shortly to be expanded to include a version with three turrets and three Y-axes respectively.

L a s e r- s i n t e r i n g is well known as the technology of choice for ensuring the quickest route from product idea to market launch.

Companies from a broad range of industries are using this technology for e-Manufacturing — the fast, flexible and cost effective production directly from electronic data for every phase of the product life cycle.

The Eosint M 280 is the updated and further improved version of the Eosint M 270, the system on the market for the additive layer manufacturing of metal components. It directly produces top-quality metal parts on the basis of three-dimensional CAD data — fully automatically, in only a few hours, and with no need for tools.

Automatic Turning

Enquiry no. 6912 68 industrial automation asia | September 2012

Key To e-Manufacturing

Enquiry no. 6914

products & Services

Hioki: Memory HiLogger

LCM Systems: Relay Module

The Memory HiLogger LR8400-20 series is a multi-channel portable data logger. This model is able to measure and record temperature, humidity, DC voltage and resistance at a highspeed sampling of up to 10 milliseconds.

The LR8400-20 series comes standard with 30 fully isolated channels which is expandable to 60 channels. An additional eight channels is also provided for pulse totalisation, pulse rotations and logic input measurements. Measurement data can be simultaneously saved to external storage media and to a PC connected via LAN or USB cable.

LCM Systems has released the latest addition to the T24 wireless telemetry system for multiple data acquisition in real time. The T24-RM1 is a new generation of relay module that offers two power relays each of which can be assigned a set point and triggered from either one T24 acquisition module or a summed group of up to eight units.

The T24-RM1 dual 240Vac 5A relay modules are capable of mains power switching and have been designed as limit or window alarms for the T24 acquisition units. The relays can be latched and a digital input or external command can be used to reset them. An alarm signal relay is operated if communications is lost or other selectable errors occur. This alarm output can be silenced by a contact free digital input or external command.

Enquiry no. 6915

Enquiry no. 6917

JJ-Lapp Cable: Solar Junction

Rapidform: A Fast Path To CAD

FPE PL 008 from Lapp and FPE Fischer is a junction box made of plastic and designed to fulfill IP 67 protection rating in the photovoltaic systems. Energy efficiency is boosted by the reinforced retention of the ribbons, while moulded cable glands eliminate potential sealing issues.

The PV product portfolio is further extended with the new Epic Solar 4 connector that is compatible to the pre-assembled Epic Solar 4 Thin, has double locking hooks and is available for 2.5 and 4-6mm cables. By crimping the connector to the cable, systems installers can join the cables and the Lapp/FPE junction boxes.

The Rapidform XOR3 SP has increased automation for the reverse engineering process. The technologies save more time in creating parametric solids from 3D scans and the software automatically recognises complete modeling features in the scan data, allowing the user to create extrusions, revolutions and freeform surfaces with just a few clicks.

This cuts the modeling time from about five minutes per feature to less than one minute, an 80 percent improvement on time savings. The feature is editable either inside Rapidform or in any of the CAD applications that XOR interfaces with. These include SolidWorks, Siemens NX, Creo Parametric, and also new for 2012, Autodesk Inventor.

Box And Connector

Enquiry no. 6916

Enquiry no. 6918 September 2012 | industrial automation asia  69

products & Services

Sick: Speed Monitor

STMicroelectronics: Multi-Sensor

The zero speed and drive monitor Speed Monitor MOC3SA by Sick serves for the speed monitoring of drives. The product has four safe semiconductor outputs and is EN ISO 13849 (PL e), IEC 61508 (SIL 3), and EN62061 (SILCL 3) certified. The device also allows for easy commissioning using only a screwdriver.

Some of the applications for the MOC3SA include use of the zero speed monitoring for access monitoring (eg: machines for material processing, applications of palletising and robotics, and the use of the safety limited speed in maintenance mode (eg: machines for material processing, applications of palletising and robotics).

iNEMO inertial module from STMicroelectronics enhances user experience and motion-sensing realism in space-constrained and power-hungry portable consumer devices and shortcuts the path to wearable sensor applications in sports, fitness and healthcare diagnostics.

The LSM330 module houses a 3-axis digital gyroscope and a 3-axis digital accelerometer with two embedded finite state machines. This product targets a wide range of applications that include wearable sensor applications, motion-activated user interfaces in phones and tablets; motion detection and mapmatching for indoor/outdoor navigation, augmented reality and other location-based services.

Enquiry no. 6919

Enquiry no. 6921

Siemens PLM: Better

Rockwell Automation: Machine

Siemens PLM Software has released the Teamcenter 9, a PLM system that delivers solutions and enhancements across the portfolio in support of Siemens PLM Software’s HD-PLM vision.

The system helps companies deliver complex products while maximising productivity and streamlining global operations.

The release adds an integrated systems engineering solution and tightens the integration across the unified architecture, so companies can make smarter decisions with better visibility into the impact of those decisions.

The Rockwell Automation midrange system portfolio helps machine builders to design better performing machines, increase overall equipment effectiveness and put innovation into practice.

With motion and integrated safety, utilisation of standard EtherNet/IP and the simplicity of a single, easy to use programming environment, it is scalable, integrated control for every size of machine and every budget.The CompactLogix control platform provides scalability from two to 16 axes of motion, EtherNet/IP connectivity for enhanced data capture and exchange, and Integrated Motion and drives over EtherNet/IP.

Decision Making In Product Development

Enquiry no. 6920 70  industrial automation asia | September 2012

Control Platform

Enquiry no. 6922

Calendar Of Events 2012/13 September

5 – 7 Semicon Taiwan 2012

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

12 - 14 Medical Manufacturing Asia 2012

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

10 – 13 IGEM 2012

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

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

november

26 – 28 Thailand Lab 2012

6 – 10 Industrial Automation Show 2012

Shanghai New International Expo Centre China Shanghai World Expo (Group) Co., Ltd. Email: ciif@shanghaiexpogroup.com Web: www.ciif-expo.com/

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

21 - 24 All Industrial Expo 2012

october 3 – 5 Power Gen Asia 2012

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

4 - 6 Metalex Vietnam 2012

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

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

27 – 30 OSEA 2012

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

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

6 – 10 China International Industry Fair 2012

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

4 – 7 ConBuild Mining Vietnam 2012

5 – 7 Semicon Japan 2012

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

december

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

5 – 8 Manufacturing Indonesia 2012

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

January 30 - 1 Feb Semicon Korea 2013

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

February 1 - 3 India Automation Technology Fair Bombay Exhibition Center Mumbai, India Email: tarun.marwah@mmi-india.in Web: www.iatf.in

28 - 2 Mar IIC China Conference & Exhibition 2013 Shenzhen Convention & Exhibition Center Shenzhen, China Email: dgu@globalsources.com Web: www.english.iic-china.com/

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

Advertising Index

64

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IndustrialAutomationAsia

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486

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444

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31

482

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49

487

ALLIED VISION TECHNOLOGIES ASIA PTE LTD

57

493

CARLO GAVAZZI AUTOMATION SINGAPORE PTE LTD

37

478

COGNEX SINGAPORE INC

43

481

DENSO INTERNATIONAL ASIA PTE LTD

27

452

DIVINE INTERNATIONAL

65

492

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3

404

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5

475

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51

489

FLIR SYSTEMS CO., LTD

9

442

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7

484

HIOKI SINGAPORE PTE LTD

45

477

HEAD OFFICE SINGAPORE Eastern TRADE MEDIA PTE LTD 1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: 65-6379 2888 Fax: 65-6379 2805/6379 2806 SINGAPORE: salesIAA@epl.com.sg

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HONEYWELL PTE LTD

23

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ICP DAS CO LTD

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55

351

IGUS SINGAPORE PTE LTD

35/39

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INGERSOLL-RAND SOUTH EAST ASIA (PTE) LTS

IBC

426

JJ-LAPP CABLE (S) PTE LTD

63

488

OBC

415 479

MITSUBISHI ELECTRIC ASIA PTE LTD NCC EXHIBITION ORGANIZER CO LTD

41

ROCKWELL AUTOMATION SOUTH EAST ASIA PTE LTD

1

480

SCHNEIDER ELECTRIC SINGAPORE PTE LTD

29

491

SCHNEIDER ELECTRIC IT SINGAPORE PTE LTD

33

490

SIEMENS PTE LTD

15

483

SPECTRIS PTE LTD – RED LION CONTROLS

53

485

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KOREA:

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WE SERVE VIRTUALLY EVERY INDUSTRY Ingersoll Rand Industrial Technologies provides products, services and solutions that enhance our customers’ energy efficiency, productivity and operations. Our diverse and innovative products include Ingersoll Rand compressedair systems, tools, pumps, and material and fluid handling system.

AIR Air Compressors & Blowers Reciprocating Rotary Screw Centrifugal

TOOLS Impact Tools

- Durable, high efficiency Air Compressors

- Ergonomic designs

- Low noise level

- Built-in lubricator

- Simple installation

- Up to 3.5 inch square drives

Air-Operated Pumps

AFTERMARKET NEEDS

- Energy saving variable speed drive (VSD)

Grinders

MATERIAL HANDLING

Double

Hoists & Winches

Services Capabilities

- Horizontal, vertical and angle models

Diaphragm

Powered by

- Compressor Service

Metallic

Air

- Material removal and finishing

Non Metallic

Hydraulic

- Ergonomic desings

- Longer lasting wear parts

Electric

- Easy access major air valve

Manual

- Simplified service kits

- Up to 100 ton lifting capacity & beyond

- American Petroleum Institute (API) standard design - Solutions for virtually all Key Industrial Markets

Air Treatments Systems Designed for ISO8573.1 Air Quality Class

Needle Scalers

- Refrigerated Air Dryer

Drills

- Desiccant Air Dryer - Filters - Air Receivers

- Pistol and straight

FLUID HANDLING

- Needle scaler kit - 5” and 7” needle (19pcs)

- Maximum flow rate up to 1041 litres/min

Piston

- Up to no. 5 morse taper

- Individual pump & full packages

- Drilling (3”) and reaming (2.5”) capacity

- High performance

- Inertia and pre-engaged models

- Carbon steel & stainless steel construction (Maximum corrosion resistance)

- Left and right hand rotation

- Multiple pressure/ratios/flows

Air Starters (Engine)

- Customization

- Man lifting winches for offshore applications - Certification by ABS, DNV, Lloyds, etc

- Preventative Maintenance - Tools, Fluid and Material Handling, Servicing & Overhauls - Diagnostic and Auditing Services - Remanufacturing Technology Centre - Installation Work - Low Pressure Blower Services

Parts & Accessories Condensate Mangement - PolySep Condesate System - Pneumatic No-Loss Drain (PNLD) II - Electric No Loss (ENL) - Water Separators

- Sales, Services, Parts, Commissioning, Load Testing

Power Management

- World-wide professional repair & service network

Controls

- Variable Capacity Control (VCC) - Line Reactors - Automated Air System Controllers

System Components - Intelliflow™ - PaCE

Installation - Simplair Evolution - Receiver Tanks

Consumables - Filtration - Lubricants

Ingersoll-Rand South East Asia (Pte) Ltd 42 Benoi Road Singapore 629903 Tel: 6861 1555 Fax: 6862 2086 Sales Hotline: +65 6860 6734 | Service Hotline: +65 6860 6857 Air: irair@irco.com | Tools, Fluid & Material Handling: irtools@irco.com

www.ingersollrandproducts.com

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