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MICA(P) 154/07/2009 | ISSN 0219/5615 | PPS 1561/06/2010 (028221)

Going Wireless A Standard Procedure Safety PLCs Tools To Help You Choose Green Buildings Protecting The Environment Mobile Networking Getting Your Priorities Right

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ENQUIRY NO. 041 Copyright © 2009 Rockwell Automation, Inc. All Rights Reserved.

Copyright © 2009 Rockwell Automation, Inc. All Rights Reserved.

ENQUIRY NO. 036

contents OCT/NOV 2009

ISSUES & INSIGHTS

21

Mobile Networking: Getting Your Priorities Right

Having the ability to chose data sharing methods offers flexibility and control.

By Kelly Ungs, Intermec

24

52

Going Wireless: A Standard Procedure

The ISA100.11a standard aims to achieve a wireless network in the field where it can integrate robustly with an existing system for the process automation. By Toshi Hasegawa, Yokogawa Electric Corporation

28

Wind Power Opportunities

Of Costs & Cable Cutting

Combining wireless with wired automation systems can save you money without sacrificing control capability or reliability. By Peter Zornio, Emerson Process Management

CONTROL POINT

30

Safety PLCs: Tools To Help You Choose

Evaluation of Safety PLCs based on both technical requirements and commercial requirements are crucial when selecting one. By Mike Scott and Bud Adler, AE Solutions

32

Your Safety Certified!

Designing a safety architecture and developing a safety application is an integral part of the process.

By Christophe Cornillon, Schneider Electric

20

Plant Asset Management: Speaking EDDL

21

Mobile networking

Getting Your Priorities Right

SOFTWARE & NETWORKS

34

Networks In Buildings: A Central Role

Remote management of building network infrastructures is critical when it comes to supporting service providers who utilise third party networks. By Daniel Santos and Don Winn, Connexion Technologies

37

24

Going Wireless: A Standard Procedure

Wireless Sensor Networks & Energy Harvesting Standards

Energy harvesting can only become a multibillion dollar business if standards are created and interoperable equipment becomes more widely available. By Raghu Das, IDTechEx

INSTRUMENTATION & MEASUREMENT

38

Gas Analysers: Independent Workers

New Process gas analysers designs are able to operate hands-off over months without any need for maintenance or calibration. By Dr Michael Markus, Sick Maihak

SECTOR SPOTLIGHT

42

Process Safety In Specialty Chemicals

New standards offer more choices for integrating safety and process control.

By Art P Pietrzyk, Rockwell Automation

32

Your Safety Certified!

2  industrial automation asia | Oct/Nov 2009

ENQUIRY NO. 070

contents OCT/NOV 2009

42

ProCess safetY in sPeCialtY CHeMiCals

ENERGY

46

49

Green Buildings: Protecting The Environment

With the rising tide of environmentalism, green buildings will be the norm in ecocities of the future. By Augustine Quek

8

News

Shedding Light On The Building Illumination Market

19

Fieldbus Foundation

20

EtherCAT Technology Group

60

Products & Services

67

Calendar of Events

68

Advertising Index /

APAC consumers consider energy efficiency and long life as important considerations when buying light bulbs.

By Tonya Fowler, Frost & Sullivan

50

Building Towards A Sustainable Future

Christoph Conrad, senior VP, Building Life Cycle Management, Building Technologies, Sector Industry, Siemens tells IAA why maximising energy efficiency in buildings is so important.

By Derek Rodriguez

FEATURES

54 56

REGULARS

Ad Sales Office 68A Product Enquiry Card

Shipbuilding: Staying Afloat

Metalworking processes are a big part of shipbuilding as the industry undergoes the process of renewal. By Joson Ng

Cover: Exxon Mobil and Rockwell Automation

Guaranteeing Success With Standardisation

FDI combines the advantages and tried-and-tested concepts of both EDDL and FDT. By Daniel Grossmann, ABB Corporate Research and Achim Laubenstein, ABB Process Automation Division

59

World Demand For Water Desalination To Reach US$13 Billion In 2013 Technological advancements have encouraged the proliferation of desalination techniques.

By The Freedonia Group

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EDITOR’S PAGE

BUILT

Published by:

EASTERN TRADE MEDIA PTE LTD

(A fully owned subsidiary of Eastern Holdings Ltd) MANAGING DIRECTOR

TO LAST

Kenneth Tan ASSISTANT EDITOR

Derek Rodriguez derekrodriguez@epl.com.sg EDITORIAL ASSISTANT

Statistics show that buildings are a major source of energy consumption, especially in developed countries where commercial buildings are a common sight in the landscape.

In the US, buildings are responsible for approximately 40 percent of energy consumed in the country. In Europe, where arguably people are most aware of the need for energy efficiency, buildings are to blame for over 40 percent of the continent’s greenhouse gas emissions, according to The European Alliance of Companies for Energy Efficiency in Buildings (EuroACE).

This is where the concept of the green building comes in. The idea is clearly one that can, and has, created the sit-up-and-listen effect, both in the commercial sector and in governments.

The Singapore government, for one, has unveiled a S$1 billion (US$713 million) green not only a plan, which is to be implemented over the next five years. Of this, S$100 million has been allocated or a towards making buildings more but also present an energy efficient.

To add to this, the country’s propo- Housing and Development Board (HDB) has a S$31 million project sition economically involving the installation of solar panels in 30 HDB eco-precincts by 2015, according to the Singapore Economic Development Board. (Currently, homes built by the HDB house 80-90 percent of the city state’s population.)

Green buildings not only offer a feel-good factor or a moral victory, but also present an interesting proposition economically.

A decrease in carbon footprint might convince tree-huggers but, business being business after all, large companies with the real power to make things happen are surely more attracted by its business potential.

Siemens’ Christoph Conrad (pg 50) estimates that the company has helped customers achieve energy savings of 2 billion (US$2.9 billion) over the last 10 years, and if this figure is anything to go by, the question on everyone’s lips should be: Where do I sign up?

Green buildings offer feel-good factor moral victory,

Aisyah Wong aisyahwong@epl.com.sg SENIOR ART DIRECTOR/STUDIO MANAGER

Lawrence Lee lawrencelee@epl.com.sg GRAPHIC DESIGNER

Katherine Ching katherineching@epl.com.sg Soh Kee Seng sohkeeseng@epl.com.sg CONTRIBUTING GRAPHIC DESIGNER

Libby Goh libbygoh@epl.com.sg ADVERTISING SALES MANAGER

Derick Chia derickchia@epl.com.sg CIRCULATION EXECUTIVE

Irene Tow irenetow@epl.com.sg CONTRIBUTORS

Joson Ng, Kelly Ungs, Toshi Hasegawa, Peter Zornio, Mike Scott, Bud Adler, Christophe Cornillon, Daniel Santos, Don Winn, Raghu Das, Dr Michael Markus, Art P Pietrzyk, Augustine Quek, Tonya Fowler, Daniel Grossmann, Achim Laubenstein EDITORIAL CONSULTANTS

interesting

Jim Pinto Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

SUPPORTED BY:

EASTERN HOLDINGS LTD EXECUTIVE BOARD CHAIRMAN

Stephen Tay GROUP EXECUTIVE DIRECTOR

Kenneth Tan FINANCIAL CONTROLLER

Robbin Lim

etm

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Derek Rodriguez Assistant Editor

6

industrial automation asia | Oct/Nov 2009

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Industry News Vipa Expands Facility Herzogenaurach, Germany: After a one year construction period, Vipa has celebrated the opening of the state of the art expansion to its facilities in Herzogenaurach. The opening ceremony was attended by Mayor German Hacker and District Administrator Eberhardt Irlinger, in addition to approximately 300 invited guests from the fields of business and politics.

With approximately 8,000 sq m of additional floor space, the expansion building offers the required space for

product development and administration, as well as increased production and warehouse capacity, housing around 150 employees.

“The existing building simply became too small. For the future company development, it was absolutely necessary to expand office and warehouse capacities.” said Wolfgang Seel, CEO of VIPA, who opened the ceremony.

VIPA has invested about €8 million (US$11.7 million) in the expansion building.

(L to R) Mayor German Hacker, Wolfgang Seel, District Administrator Eberhard Irlinger

The fully automated high-bay warehouse shortens the distance for logistics. Previously, warehouse capacity was distributed at three different locations in the surrounding area. Now all products can be stored and accessed in this expansion.

“Our new fully-automated high-bay warehouse, including test facilities, is perhaps the most modern of its kind”, adds CEO, Wolfgang Seel. The intelligent and autonomous transportation robot ‘Servus’ takes care of the overall material transport within VIPA and supplies all departments justin-time.

Procentec Sets Up Asian Headquarters In Singapore Singapore: Dutch based Procentec has joined forces with regional Profibus experts in Asia to start up Procentec. From September 1, the operation will be responsible for developing and supporting the industry in South Asia, Southeast Asia and Oceania for the entire range of products, training and services.

The German Centre in Singapore has been chosen for the location of the office, being well positioned towards the region and its main industry players, underlining the importance of Singapore as hub for Asia operations.

Says Dennis van Booma, GM, Procentec: “Our operation in Singapore will allow us to better support our regional business 8 industrial automation asia | Oct/Nov 2009

partners, enhance our training and services portfolio and provide quicker response to our customers in the Asian region.”

The organisation in Singapore will be under the management (L) Dominique Chabauty of Henk Schaake, who currently (R) Henk Schaake also acts as advisor to the board for Profibus. Dominique Chabauty will be responsible for all marketing and technical matters. He currently also holds the position of president within the Profibus Association Southeast Asia.

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Industry News

Control Station Establishes Asian Presence Connecticut, USA: Control Station has announced the successful registration of its Malaysia-based subsidiary.

With its formal presence in Asia, the company offers more comprehensive product delivery and support services to process manufacturers.

“The establishment of our Asian presence is timely,” commented Dennis Nash, Control Station’s president. “The need for innovative and easy-to-use technologies is more critical than ever in the manufacturing sector both here in the United States and elsewhere in the world.”

Invensys To Provide Operator Training Simulator For LNG Plant Sarawak, Malaysia: Invensys Operations Management, a global provider of technology systems, software solutions and consulting services to the process and manufacturing industries, has signed a five-year, multi-million dollar contract to supply a comprehensive operator training, process design and operation optimisation solution to Malaysia LNG Tiga (MLNG Tiga).

Malaysia LNG Tiga is a joint venture of Petroleum National (Petronas), Shell gas, Nippon Oil LNG (Netherlands) and Sarawak State of Malaysia. The Bintulu LNG Complex houses the MLNG, MLNG Dua and MLNG Tiga plants. MLNG Tiga is the second major expansion of the complex. It will be constructed adjacent to the original three-train MLNG plant and the three-train MLNG Dua plant. It has a combined capacity of about 23 million tonnes per year, and together with ancillary facilities which include six LNG storage tanks and two loading jetties, it set to become the world’s largest LNG production facility from a single location.

The integrated operations of the three plants, supported by a current fleet of 13 LNG tankers and with additional six vessels under construction, will enhance Malaysia’s LNG supply flexibility and reliability.

Proserv Chooses Parker Fittings & Valves Aberdeen, UK: Parker has signed a worldwide representation agreement with the oil and gas systems integrator Proserv Group AS. Tube fittings, valves, manifolds and other components from the instrumentation products division of Parker Hannifin will become part of Proserv’s system building offering.

In addition to Proserv’s broad activity profile, the system builder’s worldwide footprint was a major attraction for

Parker, as it extends local support to several areas not currently covered by its own international office network, such as West Africa.

Parker’s Sheldon Banks notes: “Our agreement gives us the means to better serve oil major, design house and EPC clients - bringing mutual opportunities for rapid and sustainable growth.”

“We have a very large requirement for instrumentation products and

expertise, and Parker’s range, responsive supply chain and innovative approach gives us what we need to satisfy the ever increasing demands of our clients,” adds Proserv Group’s CEO Arve Sem-Henriksen. “The product supply agreement we have with Parker will help us to build and deliver systems very rapidly and efficiently, and provide after-sales support with products from a globally-recognised source.”

Left: Arve Sem-Henriksen CEO & president of Proserv Group AS, with Ian Huggins, division GM, Parker Hannifin, Instrumentation Products Division Europe

Arve Sem-Henriksen shaking hands with Ian Huggins 10 industrial automation asia | Oct/Nov 2009

Industry News

Massachusetts, USA: American Superconductor Corporation and Beijing-based Sinovel Wind Corporation have signed a contract worth more than US$100 million (excluding value added tax) for core electrical components to be utilised in Sinovel’s 3 megawatt (MW) wind turbines, known as the SL3000.

AMSC expects to begin shipping sets of core components under the contract in March 2010 and to complete all shipments by the end of calendar year 2011.

Sinovel has already erected several 3 MW turbines off the coast of Shanghai for the Shanghai Donghai Bridge Wind Farm, China’s first off-shore wind farm.

At the end of calendar year 2008, China had an installed wind power capacity of approximately 12,000 MW (12 gigawatts). In its June 2009 report, industry research firm Emerging Energy Research projected that China’s wind power installed base would exceed 200,000 MW (200 GW) by 2020.

Emerson Forms Human Centered Design Institute Florida, USA: Signaling an important change in technology trends, Emerson is making process control technology easier to use with its introduction of the Human Centered Design Institute. This announcement culminates more than five years of customer workpractice analysis, product development re-engineering and organisational training.

The goal is simple: make products that are not only reliable, compatible and cost-effective, but also bring about a significant improvement in ease-of-use and workforce productivity.

“Process control technologies have come a long way in the past 40 years,” said Peter Zornio, chief strategic officer at Emerson. “But the industry has invested almost exclusively on feature and technology enhancement, instead of designing around how people actually use the technology. We believe it’s time technology began serving people, instead of the other way around.”

Emerson also turned its attention to day-to-day operations, focusing on the repetitive tasks operators and maintenance staff perform and how they interface with field devices.

The primary goal of Emerson’s Human Centered Design Institute is to ensure that user work practices and improved task completion (usability or workforce productivity) are at the heart of every new product that Emerson introduces.

ENQUIRY NO. 074

AMSC & Sinovel Sign US$100 Million Contract

Oct/Nov 2009 | industrial automation asia 11

Industry News

Rockwell Automation To Host 18th Annual Automation Fair California, USA: Rockwell Automation is expected to host more than 8,000 attendees in Anaheim, California from November 11–12 at its 18th annual Automation Fair event. Manufacturing business leaders, industry analysts, and Rockwell Automation solution partners will convene at the Anaheim Convention Center to explore the latest automation solutions from business and industry experts.

“While this year has been extremely challenging, we can help our customers prepare for the economic recovery by showing them how to capitalise on their automation investments through innovative solutions,” said Keith Nosbusch, chairman and CEO, Rockwell Automation.

Keeping with the Rockwell Automation tradition to host the annual Automation Fair event as an educational forum, company executives will focus on three themes that are top-of-mind for manufacturing leaders today: plant-wide optimisation, machine builder performance, and sustainable production.

In addition to the customer-focused Automation Fair event, Rockwell will

bring together industry journalists and analysts for Manufacturing Perspectives, a global media forum where the leading news topics in manufacturing technology and automation are discussed. The forum on November 10 will include panel discussions with customers, industry analysts and Rockwell executives. Jeremy Leonard, an economist with the MAPI Manufacturers

Alliance, also will speak about the impact that global competition and innovation have on manufacturing.

The Automation Fair event includes workshops, technical sessions, industry forums, hands-on labs and exhibits that will provide attendees with opportunities to learn about the latest trends, issues and solutions for manufacturers worldwide.

Qatar To Double LNG Production By 2010

Mitsubishi Electric Wins Order In China

New Delhi, India: According to market research and analysis company RNCOS’s research on global LNG industry, ‘Global LNG Market Analysis’, rising crude oil and coal prices in the international market, coupled with the mounting pressure to develop clean power is driving the global LNG market. Japan is expected to be the leading importer, while Qatar will remain the major exporter in coming years.

As per the research report, Qatar’s economy is continuously growing despite the worldwide economic turmoil due to its booming hydrocarbons industry as well as an array of downstream initiatives. In In particular, Qatar’s burgeoning LNG industry is the main engine driving its economic growth.

Qatar is already the world’s largest exporter of LNG and production is forecast to jump to 77 million metric tonnes by 2010. In 2008, Qatar’s gas sector overtook the oil as the largest contributor to GDP for the first time in the country’s history. Gas constituted 32 percent of the state’s income in 2008, compared with 27 percent share of the oil sector.

Tokyo, Japan: Mitsubishi Electric Corp and consortium partner China Techenergy Corporation (CTEC) have jointly won an order for digital instrumentation and control systems (digital I&C systems) to be used at two 1,000 MW nuclear power plants, which will be constructed by China Guangdong Nuclear Power Holding Corp (CGNPC). The consortium order is worth approximately 10 billion yen (US$110 million).

The installed capacity of nuclear power plants in China is expected to increase from the current capacity of 9,000 MW to 60,000 MW by 2020, and up to 160,000 MW by 2030.

Plans call for more than 50 new nuclear power plants to be constructed.

Mitsubishi Electric has been strengthening and expanding its nuclear power business in areas outside Japan including China. The company is striving to further expand its digital I&C system business even for other types of nuclear power plants in cooperation with Mitsubishi Heavy Industries, Mitsubishi Corporation, and CTEC.

12 industrial automation asia | Oct/Nov 2009

Industry News

GTL Jet Fuel Approved For Use In Civil Aviation Netherlands: Shell today welcomed the release by ASTM International of a specification that fully and unconditionally approves the use of Gas-to-Liquids Kerosene blends for powering commercial aircraft.

The specification, ASTM D7566 ‘Aviation Turbine Fuel Containing

Synthesised Hydrocarbons’, approves jet fuel containing up to 50 percent GTL Kerosene for use in civil aviation. The blends will be known as GTL Jet Fuel.

GTL Kerosene is one of five GTL products that will be produced in commercial volumes by the Pearl GTL project, currently under construction by

Qatar Petroleum and Shell. The project will produce around one million tonnes of GTL Kerosene per annum, enough to power a typical commercial airliner for half a billon kilometres (equivalent to carrying 250 passengers around the world 4,000 times) when used in a 50 percent blend to make GTL Jet Fuel.

US Awards US$100m Grant For Eco-Friendly Transport Projects

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USA: The US government has announced a US$100m grant for 43 environmentally friendly transportation projects. The grant comes from the American Recovery and Reinvestment 2009 Act under its Transit Investments for Greenhouse Gas and Energy Reduction (TIGGER) grant programme.

The projects have been selected from a large number of proposals that were submitted after the Federal Transit Administration (FRA) announced the grant in March 2008.

The road projects include the purchase of hybrid electric buses in Alabama, Connecticut, Iowa, Illinois, Michigan, Minnesota, North Carolina, Nevada, New York, Oregon, Texas, Virginia and Washington to replace the diesel buses.

The project is also aimed at developing technologies to reduce global warming as well as energy consumption to lessen the country’s reliance on oil.

Oct/Nov 2009 | industrial automation asia 13

Industry News

Doosan To Acquire Škoda Power Seoul, South Korea: Doosan Heavy Industries & Construction has signed an agreement to buy Czech power plant equipment maker Škoda Power, which will provide the rights to proprietary turbine technologies used in power plants.

The acquisition gives Doosan a 100 percent equity stake in Škoda Power. The transaction is expected to be completed by the fourth quarter of 2009.

With this acquisition, Doosan now has core technologies for boilers, turbines, and generators—the three key components of modern fossil fuel power plants.

The acquisition also makes it possible for the company to expand its presence in the retrofit and other profitable power plant service markets.

One benefit the acquisition brings is that Doosan is now able to build and supply turbines for engineering, procurement, construction (EPC) projects rather than purchasing from third-party suppliers.

Another benefit is that Doosan will have a full boiler-turbine-generator (BTG) lineup, allowing it to pursue more profitable BTG package orders, a market segment open only to the top industry players. The company expects this ability to supply its own turbines to improve foreign exchange earnings by 30 percent to 40 percent on future BTG projects.

ExxonMobil To Support Women’s Economic Advancement New York, USA: Exxon Mobil Corp, in partnership with Ashoka’s Changemakers and the International Center for Research on Women (ICRW), today introduced an initiative to help women in developing countries fulfill their economic potential through technology and innovation.

The program, called Technologies to Improve Women’s Economic Livelihoods, will help identify and deploy technologies and innovations that can improve quality of life and enable women to participate more fully in income-generating activities. The program is part of ExxonMobil’s Women’s Economic Opportunity Initiative Rex W Tillerson, (previously Educating Women and Girls Initiative), which chairman and CEO, was launched in 2005 and has invested more than US$20 Exxon Mobil million in programs that have involved women from 64 developing countries.

“As a global technology company, ExxonMobil can make a lasting contribution by helping to identify and deploy new technologies to improve and strengthen the economic livelihoods of women,” said Rex W Tillerson, chairman and CEO. “This focus area is consistent with our own belief and experience that technology and innovation are critical to addressing many of the world’s major challenges.”

ExxonMobil’s new initiative was announced by former President Bill Clinton at the Clinton Global Initiative’s annual meeting in New York. ExxonMobil is co-sponsoring the first-ever CGI special programming focused on investing in girls and women. Tillerson participated as a panelist during a plenary session ‘Investing in Girls and Women’.

“ExxonMobil’s investments in this area aim to increase opportunities for women in developing countries to improve their economic prospects and become and remain successful business leaders and entrepreneurs,” said Tillerson. “We are pleased to support the Clinton Global Initiative’s new focus on investing in women, which reflects the world’s growing recognition of the critical role of women in delivering high returns for economic and social development.”

14 industrial automation asia | Oct/Nov 2009

N-Tron Announces Distribution Alliance With Opto 22 Alabama, USA: N-Tron Corporation has announced a strategic marketing and sales agreement with Opto 22.

As part of the agreement, Opto 22 will resell N-Tron’s industrial Ethernet switches and wireless access points to their customers.

Said Warren Nicholson, N-Tron CEO and president: “Our two companies’ products complement each other perfectly and having them available through Opto 22 creates a single-source for engineers and other automation professionals looking for the components to solve process and machine control, monitoring, data acquisition, and networking communications challenges.”

3D Systems Acquires Acu-Cast Technologies South Carolina, USA: 3D Systems Corp has acquired the assets of Acu-Cast Technologies. 3D Systems expects this acquisition to be accretive to its future operating income.

C o n c u r r e n t l y, 3 D S y s t e m s announced the launch of 3Dproparts, a rapid prototyping and manufacturing parts service.

Evonik & Vega Extend Framework Contract Schiltach, Germany: Vega and Evonik have extended their existing framework contract by another 3 years.

The framework contract is valid until June 30, 2012. It covers the delivery of Vega level measurement and switching technology to the manufacturing locations of Evonik Industries around the globe.

Industry News

Wireless Network Carriers Take Up Slack On Infrastructure Spending keen to exclude Chinese vendors. While the Indian subscriber market is still one of the fastest growing, and largest, average revenue per user is one of the lowest in the world.Indian carriers therefore have a narrower margin to remain profitable, and yet India has some of the most intense competition within its borders, and 3G licensing has just been completed.

The YoY growth in installed basestations will drop to 6.5 percent for 2009.

However there are healthy signs that vendors such as Alcatel-Lucent, Ericsson, Nokia-Siemens, and others, are starting to ship 4G LTE equipment.

ENQUIRY NO. 075

Singapore: “Mobile network carriers in developed markets mobile carriers are picking up the slack on infrastructure are expanding their 3G footprints spending, increasing it up 8 percent and upgrading existing infrastrucquarter on quarter,” says Jake Saunders, ture to support HSDPA/HSUPA and VP for forecasting at ABI Research. even HSPA+.”

“However, 2009 is still likely to close In Asia, the Chinese and Indian down 4 percent to 5 percent compared markets are likely to make marked to 2008.” contributions to equipment vendor While the global economic outlook revenues. Despite the fanfare of a has swung from inventory doom and third round of contract awards for gloom to stock market euphoria and TD-SCDMA, China Mobile will need to back to an overcast, ‘where’s the roll out TD-SCDMA for several years to demand?’ scenario, mobile carriers have build out the coverage and quality of their sights set on the mobile broadband service to meet end-user expectations traffic tidal wave that is rippling through and traffic build-up. In China, the lion’s their networks. share of contracts have gone to Huawei, “There has been a noticeable shift ZTE and Datang. in spending towards 3G and 3.5G In India, while there has been a equipment,” Mr Saunders continues. degree of scaremongering among “GSM infrastructure is still selling off politicians about contract awards, PCA2010 MagAd(IndAuto)p.fh 2:50but PM Page 1 the shelves for emerging9/28/09 markets, Indian mobile operators will not be

Oct/Nov 2009 | industrial automation asia 15

Industry News

Metso To Enter Solid Waste Recycling Equipment Business Helsinki, Finland: Metso and M&J Industries A/S have signed a sale and purchase agreement according to which Metso will acquire 100 percent of the shares in the Danish company M&J Industries A/S. The value of the transaction is about €16 million (US$23.4 million) and it is expected to be closed soon.

This acquisition strengthens Metso's position as a supplier of recycling equipment and services and makes the company a player also in the solid-waste recycling equipment segment.

“With the acquisition, we are taking an important step in strengthening our capabilities to serve our traditional metal recycling equipment customers who are expanding their scope to also cover the

recycling of other types of materials.

An exciting new customer segment is energy companies that use this kind of equipment in the pre-combustion treatment of solid waste and biomass in their power plants. We already supply the segment with our power generation and automation products and services. Crushing technology has always been one of Metso's core strengths, and this acquisition expands our crushing capabilities to cover solid waste applications as well as the current metal recycling and rock crushing applications,” says Christoffer Ribbing, president of Metso's Recycling business line.

GM India & Reva To Develop Electric Vehicles For Indian Market New Delhi, India: General Motors India has announced that it has entered into a collaboration agreement with Reva Electric Car Company to develop electric vehicles for the Indian market. Both companies, in partnership mode, will develop car platforms, electric vehicle technology and advanced control systems.

Stating that the development of small electric vehicles was a growth area around the global automotive industry, Nick Reilly, president of GM International Operations, said that this cooperation with REVA in India will accelerate GM’s progress to meet the emerging needs in many parts of the world.

NUS Fuels Eco-car Innovation With MSC Software Singapore: MSC Software have announced that National University of Singapore (NUS), one of the leading global universities centred in Asia has achieved tremendous success in Eco-car innovation and competition using the company’s engineering analysis tool, MSC Adams.

The NUS eco-car, KRUCE (Kent Ridge Urban Concept Eco-car) runs on hydrogen fuel cell and was ranked top five in the recent Shell Eco-marathon competition that saw 66 entries from 37 different countries.

The Shell Eco-marathon is an educational platform that encourages innovation, reinforces conservation and fosters the development of leading technology for greater energy efficiency.

At the end of the competition, there were only 28 teams that managed to complete at least one of the three runs. As a testament to NUS’s engineering ingenuity, the eco-car team arrived in time to take part in one run only during the global competition and that run was good enough for a top five placement.

Both companies have already begun feasibility studies of GM’s vehicle platforms to host the electric technology and are expected to announce more details about the vehicles soon.

The collaboration to bring affordable small car platform based electric vehicles to the market is in line with government objectives to reduce fossil fuel dependence.

Agilent Technologies Opens Centre For Systems Biology Shanghai, China: Agilent Technologies has announced the opening of the Shanghai Institute of Biological Sciences (SIBS)-Agilent Center for Systems Biology in Shanghai, China.

The centre will feature multiple technology platforms in the areas of genomics, proteomics and

16 industrial automation asia | Oct/Nov 2009

metabolomics to conduct biomarker identification to better understand diseases.

“As a leading provider of bioanalytical instruments, Agilent is very proud to be collaborating with worldclass life science researchers who are contributing to breakthrough research

in China,” said Nick Roelofs, president of Agilent's Life Sciences Group.

“China has demonstrated tremendous progress in recent years in technological advancement and research capabilities and is a key focus area for Agilent's Life Sciences Group.”

Industry News

Dematic To Supply Mechanised Logistics System Luxembourg: Dematic has won the contract to supply the mechanised logistics system for Tesco’s 910,000 sq ft distribution centre (DC) in Teesport, Middlesborough. The system, which is scheduled for completion in 2010, will provide the UK retailer with a pallet storage solution, incorporating a fully mechanised high bay warehouse, monorail and conveyor networks, and a Warehouse Control System (WCS).

Dedicated to Tesco’s fast-growing general merchandise range, the new DC is the company’s first purpose-built import centre. Located on a brownfield site next to a deep sea port and the forthcoming ‘Northern Gateway’ container terminal, the

centre will eliminate the need to transport imported goods in bulk to distribution centres further inland. As a result, Tesco will realise significant cost savings on its inbound logistics operations.

Furthermore, the environmental benefits include a reduction in CO2 emissions of over 700 tonnes per annum.

The Dematic system includes a total of 43 automated storage and retrieval cranes and 120,000 pallet locations. As well as supporting full pallet picking, the high bay warehouse will also replenish a low bay picking area where mixed pallets can be generated. The goods in, storage, picking and despatch areas will be linked via extensive monorail and conveyor systems.

Siemens Merge Divisions New York, USA: Effective October 1, 2009, Siemens Energy & Automation, Siemens Transportation Systems, Siemens Building Technologies, and Siemens VAI Services will merge, and the resulting corporation will be renamed Siemens Industry. Daryl D Dulaney, 56, has been appointed as president and CEO of the

newly-formed Siemens Industry.

Since 2007, Siemens has been globally aligning its businesses into three sectors: Healthcare, Energy and Industry.

Siemens Industry will provide its wUS customers in the fields of industry and infrastructure with integrated automation technologies as well as comprehensive

industry-specific solutions.

With more than 30,000 employees in 480 locations across the country, Siemens Industry will consist of six divisions including Industry Solutions, Industry Automation, Drive Technologies, Building Technologies, Mobility and Osram Sylvania.

Oct/Nov 2009 | industrial automation asia 17

Foundation Fieldbus For FPSO Seminar

The Chevrons in Singapore played host to the Foundation Fieldbus For FPSO (Floating Production, Storage and Offloading vessel) seminar on August 21, 2009, bringing together end users for a day of presentations and live demonstrations.

Speakers included Andreas Agostin, president, Fieldbus Foundation Marketing Society, who talk about the market outlook, and Hisashi Sasajima, VP, Fieldbus Foundation, Asia Pacific Operations, who provided the Asia Pacific Marketing Update.

Growing Market The FPSO market has been growing rapidly with annual 18 industrial automation asia | Oct/Nov 2009

FPSO installations and demand steadily on the rise. One reason is because FPSOs offer a flexible and economically attractive drilling solution. FPSO is also the only solutions with significant storage capacity.

The difference in FPSO and non-FPSO applications lie in the selection of components.

All system components (power conditioners, field devices, control systems, cables etc) have to be certified for marine applications (corrosive effects, vibration etc).

The components have to be chosen in order not to increase the net weight of the platform.

Utilising Foundation fieldbus as the standard for FPSO applications

offers a substantial overall cost saving and makes the maintenance simpler. Other advantages of using a Foundation fieldbus system include: • Increased availability • Reduced capex • Reduced operational and maintenance expenditure • Easy integration with business enterprise • Reduction of cycle time • Reduced driving exposure and hostile environment Advantages Of FF In FPSO Emerson’s Jonas Berge revealed the advantages that a Foundation fieldbus architecture can bring compared to conventional local I/O

information between devices on different H1 networks at different ends of the plant. Controls can therefore span between process cells and a plant area.

August 21, 2009 The Chevrons Singapore ENQUIRY NO. 7101

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ENQUIRY NO. 071

wiring, such as savings on wiring, real time status and feedback, increased device diagnostics, real number data transmission etc.

ABB’s Jack van der Horst’s then discussed the benefits of using HSE (high speed Ethernet). In addition to the same life cycle benefits as H1, HSE provides the control backbone that integrates all of the systems in the plant. HSE provides peer-topeer communication capability; devices communicate with each other directly without having to go through a central computer.

Furthermore, HSE can bridge

STEP is a registered trademark of Siemens AG

(Top) Andreas Agostin addressing the crowd (Bottom) Jonas Berge points out that a Foundation fieldbus infrastructure is needed to benefit from devices like high density temperature transmitters and machinery health transmitters

Oct/Nov 2009 | industrial automation asia 19

Asia SECURITY concerns accompany the introduction of Ethernet in automation: do EtherCAT users now have to invest the costs saved by EtherCAT into expensive security measures?

The methods known from the IT world such as firewalls, usage of up to date virus scanners and password protection are security measures which also have to be considered for automation networks.

Security:

saves costs, but also by nature avoids the basis for most security issues. IP based protocols are tunnelled by EtherCAT: addressing, timing, bandwidth allocation and protocol environment remain within control of EtherCAT. An EtherCAT segment therefore builds a zone, for which it is generally sufficient to protect the ‘tunnel entrance’ in order to keep the entire EtherCAT network clean. If necessary, one can omit

its components, which require no IT specialist knowledge at all. With EtherCAT no router and switch configuration or their analysis and real-time optimisation is required.

The same principle also applies regarding IT security: If via EtherCAT remote access towards the control system is enabled, then this access has to be secured by appropriate measures. Which measures are appropriate mainly depends on the application and

A Topic For

EtherCAT Networks?

Zone Concepts However, in industrial automation there may be limitations in using those provisions. Current concepts are based on zone concepts, which define specific entry points into the production network. Within a zone an unauthorised access has to be ruled out. Open entry points such as router or switches thus have to be avoided within the zone.

EtherCAT is an industrial Ethernet technology: it uses standard Ethernet frames, standard Ethernet cables, and of course also the internet technologies such as TCP/IP, FTP etc are supported as well.

But the EtherCAT-Protocol is directly using the Ethernet frame, and itself is not IP (Internet Protocol)-based. Thus within the EtherCAT basis protocol the most common transport means for cyber attacks is missing. EtherCAT devices do not need a TCP/IP stack for process data and parameter communication. This not only 20

industrial automation asia | Oct/Nov 2009

the tunnel mechanism entirely for particular sensitive applications – then all IP based protocols remain outside the network; they are not required for configuration or operation of the network.

Even if the EtherCAT frames negligent or intentional other p ro t o c o l s ( s u c h a s T C P / I P frames) are inserted, this does not lead to a security breach: nonEtherCAT frames (identified by their Ethertype) are discarded by the slave controller chips – and thus by hardware and not by a software stack, which could be manipulated. Furthermore, within an EtherCAT segment switches and router are not used, so side entries are avoided as well.

Effective Technology With EtherCAT the following basic principle applies: as much IT technology as necessary, not as much as possible. This is valid regarding the required knowhow for configuration, setup and maintenance of the network and

the control system itself, and does not depend on EtherCAT. EtherCAT itself provides best prerequisites so that these measures can be limited to the control system itself. If EtherCAT is used like a classical fieldbus – just much faster, with less configuration effort, flexible topology and reduced costs – then the security effort is also comparable with the one used with fieldbus systems.

If TCP/IP is used as well, this does not mean that expensive security infrastructure components and other complex security measures are required. Sense of proportion and the right technology choice thus are the crucial ingredients for the security concept of an application. By its functional principle the EtherCAT technology automatically supports common security means and avoids the access by TCP/IP based attack scenarios.

ENQUIRY NO. 7102

ISSUES & INSIGHTS

priority-based networking system is one where different types of data have varying values and are transmitted in ways suitable to their importance to the company. Data should be made available to backend systems as they are required, whether it is for status reports, lists of parts sold, time spent on a call or captured mileage. This is a cost versus need data model. The more urgent the need for the data, the higher its

Mobile Networking:

priority for being sent to the server in the quickest, and often most expensive way possible. The lower the urgency, the slower and less costly the method of transmittal.

Priority-based mobile systems normally require more than one way to collect and share information in order to provide a high level of service at an affordable price.

In the best of worlds, the mobile application and the rugged hardware work in concert to auto-

matically determine how and when data should be handled.

Such integrated software and ha rdwa re a re ava ilable for implementation today.

Priority-Based Applications Priority-based applications that have a mobile component, where real-time data collection and sharing enterprise-wide is essential to the operation of a business and the satisfaction of its customers,

Having the ability to chose data sharing methods offers flexibility and control. By Kelly Ungs, network communications product manager, Intermec

Getting Your Priorities

RIGHT

Wireless capability is usually considered essential to the successful implementation of priority-based systems

Oct/Nov 2009 | industrial automation asia 21

issues & insights

require special considerations.

That’s especially true if those applications are regional, national or global in nature.

By definition, a priority-based application should provide mobile workers with access to company and customer records, as well as the ability to update those records from the field. Wireless capability is usually considered essential to the successful implementation of such systems.

The decision to go wireless should be based on cost vs need: how much data do you need in real time, how much can you analyse, how quickly can you analyse it and make it beneficial, and is it necessary to stay competitive in the marketplace.

What does it take to build a true around-the-clock total solution system that captures every piece of data for decision making, pro duc t t rack i n g, bu si ne ss automation and strong bottom line productivity?

You need a strategy and a plan.

Your business strategy will drive an integrated software and hardware, and communication plan that fits the needs of your operation and various methods of transmitting data based on its value to the organisation.

What Makes The System?

Components of a total solution system include: • A handheld mobile computer tough enough to stand up to the environment in which it will operate – rough handling, indoor and outdoor temperature extremes, and solid state memory so it doesn’t lose any data if the battery dies.

It must also have the ability to run the mobile application and be compatible with the applications residing on the company server.

• Mobile computer application software, designed to operate 22 industrial automation asia | Oct/Nov 2009

A priority-based application should provide mobile workers with access to company and customer records, as well as the ability to update those records from the field

in wired or wireless environments and support all the business processes needed by the remote worker.

• A wireless radio module such as a PC card integrated into the handheld, vehicle-based, or data compatible cell phone and a wireless service provider to carry messages back and forth between the field force and the central server.

• A communication gateway that can: handle wireless data communications; initiate and accept sessions, track data to ensure it is received, monitor the entire communications effort, support dial-up service if wireless is not available, offer Ethernet capabilities and a system administration function to prioritise data messages so least cost versus data delivery need can be managed.

• An application server, which prov ide s a ce nt ra l dat a repository for all the information moving to and from the mobile worker and provides a single point of integration into host systems such as enterprise resource planning (ERP) or customer relationship

management (CRM) and for dispatching and prioritising data.

• Integration of all hardware and software components by internal staff or an outside systems integrator familiar with the application and an implementation of this type.

While this type of system may be more costly to implement than a stand alone pager or cell phone, it offers definite benefits that can directly impact the bottom line, like enhanced productivity and decision making, and improved customer satisfaction. In this process, the mobile worker enters the data only once through a touch screen or keypad on his mobile computer. The increased revenue and decreased expenses associated with this type of installation make the total cost of ownership of a mobile computing solution less than that of a less robust manually intensive system. The flexibility of various data transmission types also means each system can be more efficient, and data costs better controlled.

A number of key factors drive business to this type of a priority

Mobile workers have immediate access to data that is constantly being gathered and updated to make better decisions

based system. Most often it is the desire to eliminate paper and the labour-intensive manual processes that surround it, particularly the typing in of information handwritten by the mobile worker.

The problems with this multistep process include additional cost and delay in data gathering, an increase in errors, lack of complete information and the selective capture of information, which makes data analysis difficult if not impossible.

Significant Benefits The business benefit of a prioritybased mobile system is further expa nded by capturing a nd feeding data into ERP or CRM systems for analysis. Once in the systems, management can pull information to meet the specific needs of the marketing, sales, finance, purchasing and service departments. Access to timely data in areas such as inventory management and business performance provide opportunities for strategic decision making and improvements to operational efficiencies.

By enabling wireless data collection and reporting for workers in the field using mobile computers, a company gains several distinct benefits: • The ability for management to make faster decisions to eliminate work, to reschedule a call to a different mobile worker in order to meet a time commitment to a customer, to get the mobile worker to a customer location faster than usual, thus making him more billable, and to improving productivity, and • The ability for both the mobile workers and managers to have immediate access to data that is constantly being gathered and updated to make better decisions and improve the quality of service to the customer.

Outside a building, wireless data communication comes with a cost. While wide area wireless connectivity is essential for collecting and deploying realtime data for mobile workers, it tends to be the most expensive and least reliable method for data exchange.

Companies using paper-based data collection and reporting systems, or even standalone beepers or cell phones and personal digital assistants (PDAs), usually collect basic information needed for billing on a piece of paper: a list of materials used (or goods ordered) on a call and the hours spent at the location. In this multistep scenario, significant data must still be manually entered, audited, edited and decoded and the mobile worker does not always have the ability to print a formal receipt for the customer.

The majority of information collected on the job by the mobile worker could be downloaded at the end of the day, because the data is not critical enough to send via wireless methods.

On the other hand, wireless enabled mobile computers for priority based applications have the ability to: • R e m a i n f u l l y f u n c t i o n a l regardless of the availability of wireless coverage.

• Communicate using a variety of methods, including wireless, dial-up or Ethernet.

• Help to match the worker with the skills required to do the job, where wireless is used to update the status of each tech, making matches more efficient.

• Improve data accuracy and reduce manual re- entry of information.

• Print remotely so, for example, invoices or receipts can be issued on the spot.

• Enforce business rules and add consistency to the data collected before the worker can proceed to the next job.

• Control which version of application software resides on the handheld, and.

• Know where mobile personnel are at any given time.

The success of mobile computing is based on the ability to accurately capture and share data electronically and to enforce a method of data collection that consistently meets the business needs of the organisation.

Having the ability to chose data sharing methods – based on cost and speed - ranging from real-time wireless to end-of-the-day dial up, offers flexibility and control. In addition, data shorthand reduces data transmission times and enhances security.

When you set out to build a priority-based system for your business, look at the advantages of the various options and choose one that’s right for you. It could mean a boost to your bottom line.

ENQUIRY NO. 7201

Oct/Nov 2009 | industrial automation asia 23

ISSUES & INSIGHTS

Going Wireless:

Standard

P R O C E D U R E

The ISA100.11a standard aims to achieve a wireless network in the field where it can integrate robustly with an existing system for the process automation. By Toshi Hasegawa, project leader, technology marketing dept, marketing division, industrial automation business headquarters, Yokogawa Electric Corporation he standardisation effort of the wireless communication system applied in process automation (PA) field including chemical plants is gaining attention.

This activity started in two or more standardisation organisations in 2005, and is now shifting from the standard development phase to the phase in which the conformance is attested. Compared to 4-20mA and Foundation fieldbus, the communication technology of this wireless network adds the following benefits: • The reduction of the wiring at site for the temperature and pressure transmitters, and the associated engineering cost.

• Enabling the installation of sensors on places where the installation was once difficult.

• Improvement of plant safety by the collection of diagnostic data from the field instrument.

Recently, our compa ny a nnounced that it is promoting efforts to develop the ISA100.11a wireless communication standard for the process automation industry.

Based on this standard, Yokogawa will develop a field digital network platform that will enhance productivity by eliminating the difficulties users currently face with incompatible wireless communication protocols and making possible the systematic integration of wired and wireless technologies.

This article will introduce ISA100.11a’s approach as the industrial wireless communication standard: Costs & Expectations An industrial wireless network not only reduces the cabling cost but also the cost incurred during the life cycle of the plant.

24

industrial automation asia | Oct/Nov 2009

• Installation cost The reduction of communication cables and ducts, the resulting decrease of the engineering costs of the hardware and shortening of the instrumentation construction period can be expected. A significant cost reduction is expected in a chemical plant that requires cabling that needs to withstand a harsh environment or has explosion-proof demand.

• Operation cost Enabling monitoring of equipment scattered in remote places or where the installation was economically difficult, now becomes possible by installing wireless sensors.

The operation cost of the plant is expected to be decreased due to a better process control by using measurements from these wireless sensors.

Figure 1: Network Architecture Regulating System DCS

Equipment Management

Backbone Network

Wireless Lan Network

Wireless Sensor Network

The process automation system that applies wireless communication technology is generally composed of a wireless LAN network, a wireless sensor network and a wireless backbone network

• Maintenance cost The extension of the equipment life is an important measure of the productivity enhancement, and the shift from breakdown maintenance to preventive maintenance is the objective of current maintenance activities.

To achieve this maintenance more efficiently, the introduction of the device diagnosis technology becomes important. It is necessary to introduce more sensors to collect necessary diagnostic information. Wireless communication makes this a possibility.

Moreover, it is also possible to collect diagnostic information wirelessly by adding a wireless communication adaptor to existing wired field equipment.

• Restructuring cost Once the infrastructure of wireless communication is up, we can easily perform any addition or movement of a wireless sensor easily. For instance, cable re-wiring becomes unnecessary in an experimental plant, and the reduction in the construction cost and shortening at the construction period can be achieved easily.

• Safety cost A plant accident that leads to loss of lives and damage to equipment and the surrounding area should be avoided at all cost. The confirmation of a device status and a field operator’s position in the plant are indispensable information for safe operation. The monitoring of vibration or temperature of an equipment, or monitoring of dangerous gas leaks etc become feasible by installing a wireless sensor. Moreover, a field operator’s whereabouts become trackable with a wireless electronic tag and a wireless mobile terminal.

Area Of Network Architecture & Standardisation The process automation system that applies wireless communication technology is generally composed of three main networks: a wireless LAN network communicating with wireless IT equipment, a wireless sensor network and a wireless backbone network. A wireless backbone network covers the entire factory, and connects the wireless sensor network and wireless LAN network with a supervisory system.

Figure 2: ISA100 Family Backhaul Network WG15 Trustworthy Wireless WG14 Power Sources Interest Group

ISA100.11a WG3 WirelessHART Convergence ISA100.12 Factory Automation WG16

The ISA SP100 committee oversees the standardisation effort of wireless communication to apply to an industrial field

To introduce these three networks into an industrial application, an integrated approach is needed. The ISA SP100 committee oversees the standardisation effort of wireless communication to apply to an industrial field (Figure 2).

The standardisation of wireless communication is an important approach to achieve a multi-vendor environment. For the user, it means • A higher degree of freedom to choose substitute products

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Moreover, it is expected that the field operation will improve largely because the field operator can now carry a wireless handheld terminal, which communicates the field information wirelessly to the control room. It also means that fewer skilled field operators will be needed.

Oct/Nov 2009 | industrial automation asia 25

issues & insights

• The same infrastructure environment and engineering tools can be used • Investment cost minimisation with long-term stable use as the existing host application can be reused.

Sensor Network The wireless sensor network is attracting attention in the PA field. However the implementation of this technology is still not plant-wide, reasons being: 1) The elements necessary for industrial wireless, like reliability, real time updates, resistance to environment, explosion-proof requirement, electrical wave interferences and security, were not completely addressed.

2) A wireless infrastructure may consists of two or more networks if the system is constructed with products of different standards (because a common communication standard doesn’t exist), thus making multi-vendor interoperability difficult.

It is thought that the WirelessHART specification of the HART Foundation a n d t h e I S A 10 0 .11a sp e c i f ic a t io n o f t he ISA100 committee will become core wireless communication standards for the process automation.

These wireless technologies cater to non critical applications where the data collection cycle is comparatively long.

WirelessHART is a specification enhanced to transmit the HART protocol with radio signals, and it was issued as HART specification ( Ver 7) by the HART Foundation in September, 2007. This standard is for HART devices only.

On the other hand, the standardisation effort of the ISA100 committee is a democratic development process.

The ISA100.11a standard aims to achieve a wireless network in the field where it can integrate robustly with an existing system for the process automation. It is contemplated to be applied to applications ranging from monitoring to closed-loop control.

The specification of the physical layer adopts IEEE 802.15.4 using the 2.4GHz unlicensed band.

The modulation method adopts the DSSS (Direct Sequence Spread Spectrum) method, which has the highly reliable function that decreases the influence of electromagnetic noise. The data link layer has a flexible function to adopt a hybrid method to combine TDMA (Time Division Multiple Access) and CSMA

A prototype wireless transmitter using the ISA100.11a draft specification exhibited at the ISA100 Kyoto conference

(Carrier Sense Multiple Access). The network layer can easily achieve cooperation with the IT equipment such as mobile sites using IPV6 Internet technology.

As for the application layer, co-existence with existing wired instrumentation system using various communication protocol and migration to wireless instrumentation must be considered.

Wireless transmission security is improved by data encryption, and any illegal invasion to a wireless network is prevented by a Join Key and Network ID. These are just two of the many security measures being proposed.

The standardisation of wireless communication is an important approach to achieve a multivendor environment.

26 industrial automation asia | Oct/Nov 2009

Other Areas To answer the user’s needs beyond the ISA100.11a specification, subcommittees, working groups (WG), and examination groups are discussing the standardisation of various related technologies in ISA100 (Figure 2). The product for the ISA100 standard will also be used in factory automation in future. The other activities are described as follows.

• W i r e l e s s H A R T/ I S A10 0 .11a i n t e g r a t i o n examination subcommittee: ISA100.12 In ISA10 0, the ISA10 0.12 ( Wirele ssH A RT Convergence) subcommittee was established to examine the integration of ISA100.11a and WirelessHART. In ISA100.12, the objective is to solve a co-existent problem for the user who has already implemented WirelessHART, and intends to introduce the ISA100.11a product in the future.

• Wireless backhaul backbone network working group: ISA100.15 Because not only critical information from a wireless sensor but also the traffic of the IT data such as images and files is generated on a wireless backbone network, it is necessary to consider not only the separation of the control and IT traffic, but also the communication priority according to importance of information and a real-time demand of the data. Moreover, the connection point with the communication system for an existing regulating system is recommended to be limited to a minimum to conform to cyber security measures because there is a possibility that an illegal access in wireless communication.

The purpose of this working group is thus to make guidelines to use a wireless plant-wide network more safely, especially in applications with large area remote monitoring or field mobile equipment.

• Power Sources interest group for wireless device Many of current industrial wireless devices can attain a battery life of about five years by installing the primary battery, and updating data at a low-speed cycle. It will be necessary to consider high-speed data update with respect to cost, concern for the environment, and for control application in the future.

The investigation and research on the power supply technology for the radio device are currently in progress.

• Wireless working group for FA: ISA100.16 When the specification was settled in April, 2009, working group WG16 was recruited to help standardise a wireless communication for Factory Automation (Request for Proposal). It differs from the ISA100.11a specification for PA, with the application demanding for high-speed response (Latency: 250msec) for both control and monitoring.

Standard Compliance To achieve multi-vendor wireless sensor network environment, ensuring the interoperability of the wireless communication between equipment becomes important. The mechanism (the evaluation of the third party whether each product complies with the wireless communication standard and the compliance) is needed.

As for WirelessHART, the compliance registration only began in the middle of 2009 though HART (Ver.7) was released in 2007.

ISA100 WCI (Wireless Compliance Institute), under the organisation of ISA, was established for this purpose. The preparation of the compliance test environment to do the certification of conformity to the ISA100.11a standard is in an advanced stage now.

Products that pass the compliance test earns the right to display the compliance logo on the main body, and symbolises that it is a ISA100.11a product. The compliance activity is expected to begin in 2010 after the ISA100.11a standard is released.

ENQUIRY NO. 7202

How Can A Chemical Plant Apply Wireless Technology?

• Equipment diagnosis By continuously monitoring the vibration and temperature of rotating equipment such as motors and pumps with wireless sensors, it becomes possible to switch from current preventive maintenance to predictive maintenance, which contribute to the reduction of the maintenance cost.

• Process monitoring of transportation container and rotation type reactor As for the process monitoring of transportation containers and moving parts such as rotation type reactors, monitoring was difficult

with wired sensors. Wireless sensors enable monitoring easily and result in improvement in production efficiency.

• Finer process control by increasing measurement points By increasing the number of measurement points wirelessly, it enables us to understand a reactive process in greater detail, thus improving the product quality and reduces off specs goods.

• Temperature monitoring of pipeline The pipeline temperature may increase during the transportation of fluids with high viscosities. In this case,

wiring for the sensor along a long pipeline is not economical although it is critical to monitor the temperature to evade blocking by coagulation.

A wireless temperature sensor can resolve this problem.

• Dangerous gas leak detection A lot of hazardous locations exist in a chemical plant. For this case, it becomes possible to observe a lot of points by introducing wireless sensors.

Moreover, field operators will be less exposed to these hazards by having to do fewer rounds of manual checks.

ENQUIRY NO. 7203 Oct/Nov 2009 | industrial automation asia 27

issues & insights

Costs Of

Combining wireless with wired automation systems can save you money without sacrificing control capability or reliability. By Peter Zornio, chief strategic officer, Emerson Process Management

&Cable Cutting

R

eviewing the excellent recent growth of wireless field communications to monitor or gather data from smart field devices, you may have developed the notion that the use of wireless is limited to existing process plants. Two recent studies show otherwise; wireless is very well suited to capital projects.

Wireless has already made a substantial impact with hundreds of successful installations in existing plants, but this technology definitely has a place in the design toolbox for new or upgrading of facilities as well. The most compelling reason is that wireless instrumentation can be implemented at a significantly lower cost than traditional wired systems without a loss of control capability or reliability.

Wireless Savings A study by JDI Contracts of Cohasset, Minnesota (USA), working in conjunction with an engineering procurement contractor (EPC) and a major US chemical company, concluded that wireless devices could replace wired instruments for non-safety related low-speed control and monitoring applications on about 25 percent of the points in a proposed process plant.

A savings of about 10 percent was projected on the overall cost of engineering, construction, and startup when compared with those costs for wired HART enabled devices, the most prevalent method in use today.

According to Roger Hoyum, principal engineer of JDI Contracts, the largest cost contributors with wired systems are the conduit from junction boxes to field devices and labour for terminations, both of which are essentially eliminated with wireless. The cost of constructing wiring trays, cable, and labour becomes more significant in large plants with longer runs.

In addition, the study indicated certain variable time savings, the largest component of which is ‘interest during construction’. For example, starting up a major capital project just one day early can save as much as US$500,000 per day of capitalised interest cost, according to Mr Hoyum. Any improvement in the start-up date 28 industrial automation asia | Oct/Nov 2009

can obviously produce significant savings, and since the automation portion of projects is often subject to delays, reducing start-up and commissioning time is a major benefit.

Mr Hoyum said: “Our study complied with best practices required to meet owner objectives, schedule, and budget, as well as less tangible outcomes such as maintainability and ease of use. With a wireless infrastructure as a key component of new projects, we can simply deliver a better plant.”

Easy Implementation In a separate study, Emerson wireless consultants calculated that wireless devices could be used on up to 44 percent of all points. Using data from a near6000-point actual greenfield project, savings of up to 36 percent on the cost of engineering and construction of the process automation system were made possible by utilising WirelessHART networks. The saving with wireless amounted to as much as US$1,376 per signal, or up to US$3.6 million, on the project under study without a loss of control efficiency.

“Wireless is an important new tool for use with HART and Foundation fieldbus instruments in capital projects.

It delivers savings, flexibility, and fast implementation.”

Roger Hoyum A substantial number of field devices met these criteria, including those for pressure and temperature measurements, discrete inputs, vibration monitors, position monitors, inputs from analytical instruments, and ‘stranded diagnostics’ on wired HART devices.

Costs for wireless in this study were based on Emerson’s Smart Wireless self-organising mesh technology, which meets the industry-approved WirelessHART standard. Each wireless device in such a network can act as a router for other nearby devices, passing messages along until they reach their designated wireless gateway. Interference is minimal, and transmission reliability is greater than 99 percent.

Flexible Application Non-quantified savings resulting from the use of wireless on capital projects accrue from simplified engineering and training, less I/O capacity, the ability to mount devices in difficult-to-reach or remote locations, the ease of making temporary installations and late changes, and easy addition of future wireless points.

This study further supports wireless technology as a replacement for wiring to many instruments in an automation system, eliminating certain costs associated with running cables through, around, or under a dense infrastructure while not interfering with the primary process control function.

ENQUIRY NO. 7204

Emerson:

Wireless Conductivity Transmitter Emerson Process Management has expanded its Smart Wireless analytical field instrument solutions with the WirelessHART contacting conductivity transmitter, the Rosemount Analytical Model 6081-C. Since more than half of end user liquid analytical applications require conductivity measurement, the wireless conductivity transmitter is an important addition to the recently introduced model 6081-P wireless pH/ORP transmitter.

The Model 6081-C is compliant with the WirelessHART communications standard making it fully compatible with a host of other wireless devices. All Emerson wireless devices, including the Model 6081-P and 6081-C, function in a self-organising network in which every wireless device in the network acts as a router for nearby devices.

WDDN_83x110 r1.pdf

8/13/09

ENQUIRY NO. 7205 2701

5:30:04 PM

ENQUIRY NO. 064

In determining which wireless devices might reasonably replace wired instruments, the Emerson analytical team considered only technology that would be available by the end of 2010, and took the conservative position of including no feedback control points.

Oct/Nov 2009 | industrial automation asia 29

control point

Safety PLCs:

Tools To

Help You Choose

Evaluation of Safety PLCs based on both technical requirements and commercial requirements are crucial when selecting one.

By Mike Scott, VP, process safety, and Bud Adler, director, business development, process safety systems, AE Solutions hroughout the industrial process control industry Safety Instrumented Systems are becoming high profile. Most companies have accepted that the performance-based standards such as ANSI/ISA 84.01, IEC 61508 and IEC 61511 are here to stay and that conformance is not optional.

A growing number of instrumentation manufacturers have recognised the steadily increasing interest that this market has shown in bringing their plants into conformance with the standards. They have responded by introducing a wide range of products that are ‘suitable for use’ in Safety Instrumented Systems (SIS). These products include sensors, transmitters, valves and valve positioners and a wide range of logic solvers.

Most users have little concern about being able to select a proper sensor, transmitter or valve positioner but when it comes to choosing from the vast array of logic solvers, they often do not know how to make a proper decision.

The problem is clear when you consider the range of choices for Logic Solvers that range from the relatively simple alarm trip architectures up through the wide variety of safety PLCs offered by about twenty different manufacturers. These PLC architectures cover the scale from simple one-outof-one (1oo1) architectures up through triple and quadruple redundant systems with differing degrees of self-diagnostics.

With all of these choices, how is a control engineer supposed to pick the ‘best’ system for his project 30 industrial automation asia | Oct/Nov 2009

and / or plant standard? If he errors on the side of conservatism, he may cost his company tens of thousands of wasted dollars by selecting a more sophisticated system than is warranted by the application. And, even worse, a simplistic system may not be in conformance with the standards and could place human life at unnecessary risk. The problem is exacerbated when all factors of lifecycle costs are considered.

Issues To Consider This paper will highlight a five step methodology, which can be applied to perform economic analysis on Safety Instrumented Systems to ensure the ‘best’ system has been selected.

1. Select an architecture for the SIS for evaluation (sensors, logic solver and final elements) 2. Perform SIL Calculations to determine Probability of Failure on Demand Average (PFDavg) and Mean Time To Fail Safe (MTTFS) based upon a given Functional Test Interval 3. Calculate Lifecycle Cost in terms of Net Present Value (NPV) 4. Calculate Benefit-to-Cost Ratio 5. Repeat above steps for each possible SIS architecture being considered for the project Steps 1 and 2 represent tasks associated with the Safety Lifecycle and are typically already being performed by designers of Safety Instrumented Systems.

Start

SIS Conceptual Design Architecture Options

Perform SIL Calculations (PFDavg)

Calculate Lifecycle

Calculate Benefit-to-Cost Ratio

No

Benefit To Cost > 1.0

Yes

No

Lowest Lifecycle Cost?

Yes

Figure 1: Economic Analysis Flowchart

Lifecycle Cost Lifecycle Cost is a technique that allows those responsible for system selection to consider all of the costs incurred over the lifetime of the Safety Instrumented System rather than just the initial purchase costs. This is especially important where the cost of equipment failure can be significant. The intent of this evaluation is to include all costs of procurement and ownership over the life span of the Safety Instrumented System.

Lifecycle Costs Procurement Costs

Description

System Design

Engineering costs associated with Front End Loading and Detailed Design

Purchase

Cost of Equipment including Factory Acceptance Testing and shipping

Installation

Construction costs associated with SIS

Start-up

Commissioning, PSAT and Initial Functional Testing of SIS

Operating Costs

Description

Engineering Changes

Engineering costs associated with maintenance

Consumption

Power, spares parts, instruments air, etc.

Maintenance

Inspection, Functional Testing

Cost of System Failure

Description

Lost Production

Cost of lost production

Asset Loss

Cost of lost equipment

Procurement costs represent costs that occur only once during life of the project. Operating costs occur over the life of the Safety Instrumented System and can be repetitive. Costs associated with system failure can dominate overall Lifecycle Costs.

A Lifecycle Cost evaluation can show one how to minimise overall cost of ownership by initially selecting the ‘best’ Safety Instrumented System architecture. The evaluation considers the costs for: design, purchase, installation, start-up, functional testing, energy, repair, a failure event, and lost production.

To obtain the complete Lifecycle Cost, all yearly operating costs are converted to ‘present value’. All future expenses are converted into their current valve, accounting for discount rate (interest / inflation).

Initial costs and the present yearly costs are added to obtain total Lifecycle Cost. The proposed architecture for each Safety Instrumented System should be evaluated for minimum Lifecycle Cost.

Benefit-To-Cost Ratio Another tool to determine if the ‘best’ Safety Instrumented System architecture has been selected is to calculate the ratio of benefits to costs on a financial basis. If the ratio is greater than one, the system is cost effective. For example if a system has a Benefit-to-Cost Ratio of 1.5, for every $1.00 invested, the system will return $1.50.

Therefore, the Benefit–Cost Ratio is as follows:

Where, B-C Ratio = The ratio of benefits to cost FNo-SIS = The frequency of the unwanted event without a SIS FSIS = The frequency of the unwanted event with a SIS EVNo-SIS = The total expected value of loss of the event without a SIS EVSIS = The total expected value of loss of the event with a SIS CostSIS = The total lifecycle cost of the SIS (Annualised) CostNT = The cost incurred due to nuisance trips (Annualised) In today’s competitive business environment sound financial justification of a project must be performed during the Safety Instrumented System conceptual design process. This should include a Lifecycle Cost Analysis as well as a Benefit-to-Cost Ratio Analysis.

Significant savings could be realised by selecting the ‘best’ architecture.

ENQUIRY NO. 7301 Oct/Nov 2009 | industrial automation asia 31

control point

Your

Safety

!

Certified Designing a safety architecture and developing a safety application is an integral part of the process.

By Christophe Cornillon, product manager, Quantum Industry Business, Schneider Electric

T

he race to increase and maintain your competitiveness, is a fine balance between greater productivity and safety factors such as the safety of personnel, plant/production tools, and also protection of the environment.

Over and above the statutory context, this approach is quite simply your duty as a responsible company.

Now, to face these challenges, it is essential that you select safety PLCs, which are IEC 61508 compliant, for use in critical processes to ensure the safety of personnel, plant and production tools, as well as the environment.

32 industrial automation asia | Oct/Nov 2009

These safety systems ensures m a x i m u m av a i l a b i l i t y a n d reliability for a host of applications including: • Emergency ShutDown (ESD) • Boiler Protection Systems (BPS) • Fire and Gas detection (F&G) • Burner Management Systems (BMS) If you are looking for an even higher standard, the most stringent regulation requirements is the TÜ V Rheinland Safety Certification Expert. Such experts can be invited to join the whole R&D in testing phase.

Meeting Safety Requirements Designing your safety architecture and developing your safety application should be a simple part of your process.

With today’s technolog y, dedicated hardware modules ( PLC controllers, digital I/O, analogue I/O) with advanced integrated diagnostics inside will help you. The safety PLC controllers of today include two processors of different brands and technologies, in which the program is executed in parallel. In case of any mismatch, the system is automatically shut down to the safe position.

With the same objective, new digital and analogue I/O modules are designed not only to offer a dual acquisition/controlling chain but also to perform continuous integrated self-testing. As a result, there is no need for double cabling or additional modules, nor the need of a specific algorithm.

For more system a nd architecture flexibility, the system will allow you to mix safety and non-safety related I/O within a single controller’s program, simply distributing the modules in the different remote I/O drops of the system. If even greater flexibility is required, you will also be able to split the safety part from the rest of the process.

Make Your Installation Safe Today’s PLCs feature a hot standby system, which showcase a processor that help meet two uncompromising challenges.

Firstly, there is the need to secure people, the environment and your production assets by switching to a safe position in the event of system failure. While at the same time, the continuity of your process is paramount and you are faced with no other choice than to exclude downtime.

ENQUIRY NO. 7302

ENQUIRY NO. 069

software & Networks

O

ne of the most critical topics to consider when it comes to supporting service providers who utilise third party networks in buildings, is the remote management of the building network infrastructures. When discussing networks in buildings, there is a large spectrum of devices that may need to be monitored.

Many of these services may fall on one of the following categories: data services, Voice over IP ( VoIP) services, or Television over IP (IPTV). There are other subcategories such as wireless communications, alarm systems, virtual tunnels and more.

The primary goal of remote management is to reduce cost, enhance service delivery, improve network uptime and standardise the processes and procedures in managing a network in a building.

Organisations that monitor these sites or buildings may also be known as Network Operation Centres (NOC) among many other names. The main purpose of a NOC is to provide support to the service provider’s end users and monitor all network infrastructure equipment. In this case, the network infrastructure company acts of behalf of the service provider by providing NOC support.

Network Operations Centre The Network Operations Centre (NOC) provides around the clock services such as alarm surveillance for buildings, switches, data, and transport equipment, change control, performance analysis, software configuration, equipment testing and translations trouble shooting for contracting telco, enterprise, and end users (the service provider’s customers).

The NOC responds to troubles or alarms that are called in directly from the end user or its agents.

Switch, transport, optical, VoIP, and data trouble conditions are resolved either by NOC’s remote 34 industrial automation asia | Oct/Nov 2009

diag nostics a nd re storation capabilities or by referral to the end user- identified agents or by field technicians. The NOC monitors and controls all aspects of alarm/trouble recognition and resolution.

NOC procedures include:

• Problem Identification The NOC attempts to identify the problem by separating resulting symptoms from the source of the problem. In response to the event, the analyst will first develop a clear understanding of the type of problem involved.

• Event Notification T h e N O C to o l p r o v i d e s automated, timely delivery and notification of network events.

The network operations analyst receives indication of the status polling or network trap report

• Fault Isolation The NOC will next determine the point of failure or fault for the identified problem. Information is then gathered from multiple sources such as the network management system, element

Networks In Buildings:

A Central Role Remote management of building network infrastructures is critical when it comes to supporting service providers who utilise third party networks.

By Daniel Santos, (ATOG) network engineer, and Don Winn, VP, network operations centre, Connexion Technologies

• Problem Resolution A resolution is achieved when the source of the problem has been accurately identified, corrected and no other failures or symptoms arise as a result of the correction, repair and/or replacement made.

The NOC becomes the central point of expertise, access, control and correlation of incidents to identify problems in the network that could affect end users in the building. NOC support is typically separated into two functions: incident and problem management.

• Incident Management The Incident Management Team follows a troubleshooting m e t h o d o l o g y to e n s u r e consistent, reliable steps are taken to isolate network p r o b l e m s a n d e x p e d i te problem identification and resolution. In order to identify and isolate network problems, troubleshooting guidelines utilised by the NOC are based upon product technology.

The Incident Management Team supports provisioning of services; end user reported troubles and alarms provided through the operational support systems (OSS).

It is further divided by technologies and expertise and subdivided into end user touch and back office support positions. Both positions are built by skill set (tier I-III). Lower tier handles physical layer problems and single call failures

Armin Hanisch, Germany

ma na ger to ols or u ser hypotheses. This information is then analysed in an attempt to isolate the problem. Once fault isolation is determined, the NOC can proceed with steps necessary or escalate to the appropriate resources to resolve the problem.

Security management is one of the most critical areas of managing a building in a network

and the higher tier handles logical and transport layer problems and more complex outage issues.

The goal of the Incident Management Team is to restore the end user’s system to preoutage performance levels in the shortest time possible, using all available means at their disposal.

• Problem Management The objective of the Problem Management group is to ensure end user networks and network elements provide the highest possible grade of service by observing trends, monitoring ser v ice performa nce a nd degradations, resolving trouble indications a nd ensuring timely and accurate software configuration changes, backups, and routine patch application.

Each site’s performance and software status is reviewed routinely and compared to the operational objectives. Any exceptions are identified and documented for corrective actions.

The Problem Management Team focuses on root cause analysis and providing a fix to the problem that caused the initial incident. The team

will leave no stone unturned to ensure a final resolution is found by looking at the process and procedure around supporting the equipment along with analysing the logs, traps and alarms to determine how to fix the problem. They also work closely with the vendors and service providers to drive them to provide software and hardware repairs.

• NOC Tools A number of different operational support systems (OSS) and element managers are connected to end user equipment to electronically collect and analyse various systems outputs and to report any anomalies and/or alarms as they occur.

A l l O S S s r e t a i n t h e collected data for a specified interval. Analysts monitor this information and systems generated reports for trends and indications of service or performance degradations that could identify developing maintenance issues before they affect end user service or SLA components.

A l l p o te n t i a l t r o u b l e conditions are recorded and tracked in NOC’s trouble Oct/Nov 2009 | industrial automation asia 35

software & Networks

management system (TMS).

The troubles are resolved by remote diagnostics, referral to the end user, referral to the vendor, or referral to end user’s service provider. The NOC monitors and controls all aspects of trouble recognition and resolution.

E ac h le ve l o f se r v ice a ssura nce ha s specific amounts of time to work on network element problems before the problem must be escalated. Escalation intervals are dependent on the severity of the trouble and are detailed in the appropriate end user interface documentation. A building will contain servers, applications, switches, routers, hubs, printers, faxes, wireless access points, video equipment and call servers.

One of the most innovative aspects of this system is that these sites are monitored remotely. There are many tools that have been developed for the network management and remote administration of these network infrastructure devices.

Some of these tools may include Remedy, Clarify, Intermapper, Netcool, NAS, HP Openview and TTI-NetTrac.

To ensure the NOC is aware of the physical and logical inventory of equipment and protocols, a database and inventory system are critical to remote management.

The inventory has a portal to the Operational Support System (OSS) platforms which maps the equipment logically a nd physica lly f rom t he building and into the tools.

Rules, thresholds and business logic can be built to allow for fault automation. World-class NOCs leverage tools a nd technology to correct faults remotely with little human intervention.

36 industrial automation asia | Oct/Nov 2009

Remote Management There are four major factors that are needed to ensure proper service is provided to monitor and provide the necessary support for the networks in multiple buildings.

1. A Network Operation Centre (NOC): Building infrastructure where all the subject matter experts in various technologies may monitor and support end user needs with the necessary resources to resolve any issue.

2. Network tools and resources: The tools and resources are the software and hardware required to ensure that all the subject matter experts can effectively monitor and troubleshoot network infrastructure devices.

Resources may include access to vendors, manufactures and other subject matter experts in the industry. These resources may require valid contracts for technical support.

3. Subject matter experts: The personnel that work in the NOC and have different technical expertise.

4. Processes and procedures: The process which has taken the forefront in enterprise management is the information technolog y infrastructure library (ITIL). This process incorporates nine different m e t ho do lo g ie s t h a t w i l l improve the mean time between failure (MTBF) and reduce the mean time to repair (MTTR).

However, the following are five primary areas which have the largest impact on networks in buildings: • Incident management is a service interruption reported from either an alarm or end user trouble.

• P r o b l e m m a n a g e m e n t identifies the root cause and fixes the problem so it does not create another incident, including building control measures into the process to ensure the fix action remains valid and working.

• Release management is typically a team of experts t hat c a n de sig n, pla n and ensure a change is implemented in a concise manner with limited or no.

• C h a n g e m a n a g e m e n t pertains to the enablement, deletion or movement of the service in the building.

There are many types of authorisations that are required at this level to ensure the affect on the end user is minimised.

• Security management is one of the most critical areas of managing a building in a network. This would include the policies and or rules designed to protect the end user, the alerts and how to deal with them and the advisories that are announced by the various vendors.

Network infrastructures in buildings have many parts that are necessary from its inception through its delivery up through the entire operation and maintenance phases. There may be many ways to manage a network infrastructure.

However, ensuring that there is a central operational location such as the Network Operations Centre (NOC) requires the dedication of many subject matter experts, a good infrastructure with the proper tools and resources that are dedicated in maintaining the organisations success.

ENQUIRY NO. 7303

Wireless Sensor Networks & Energy Harvesting Standards Energy harvesting can only become a multibillion dollar business if standards are created and interoperable equipment becomes more widely available. By Raghu Das, CEO, IDTechEx The potentially huge market for wireless sensor networks (WSN) that could involve billions of sensors needed on trees for forest fires, utility assets, buildings, pollution monitors and much more is being enabled by energy harvesters, new energy storage solutions and new ultra low power electronics. This can realise 20 year life sensors with no maintenance which is a typical target specification for the biggest potential applications.

However, critically, these systems need to be appropriately standardised for the industry to move beyond niche applications.

The standardisation involves those making the various forms of energy harvesters - such as piezoelectric, thermoelectric and photovoltaic, to the new low power circuitry to wireless protocols. Standardisation is being approached from these different angles.

The ZigBee Alliance announced in July 2009 that it will draft a standard for energy harvesting devices. ZigBee is a short range wireless protocol that uses less power than alternatives such as WiFi and Bluetooth but it has two limitations for energy harvesting - so far many devices are interoperable and secondly, the power consumed is still often

too high for most of the potential in Wireless Sensor Networks WSN where energy harvesting is needed. For this reason, other, lower power standards have gained traction in WSN. T he se ot her sta nda rds organisations in Europe and the USA are progressing standards that encompass such things as piezoelectric and vibration harvesting.

Here the only major success has been the EnOcean Alliance with about 150 companies involved with interoperable devices, mainly for use in buildings, and well over 500,000 of them installed.

• ZigBee ZigBee is already the leading standard for parts of the smart grid and the in-building wireless network market, and it already has the International Electrotechnical Commission (IEC) seal of approval. Almost all ZigBee applications rely on batteries. This is why the ZigBee Alliance will amend its standard to work with more energyharvesting devices, possibly even battery free ones.

• EnOcean The EnOcean Alliance, like the ZigBee Alliance, is a consortium

of companies whose energyharvesting standard, also like ZigBee, is open, interoperable with existing standards — from TCP/IP to ZigBee itself. EnOcean has applied to the IEC to become an official global standard for energy-harvesting devices and, following great success in Europe, has started to gain traction in North America, The Argument Not surprisingly, the ZigBee announcement has not been welcomed by the EnOcean Alliance. Even if ZigBee cannot lead to such low power long life devices, it can muddy the water and, in the view of EnOcean, perhaps infringe patents.

However, we are not necessarily seeing direct competition here. Zigbee Alliance is not standardising or developing harvested energy techniques.

It is only creating extensions to the existing ZigBee stack that would permit OEMs to use a greater selection of available energy-harvesting solutions.

Both sides agree that you cannot get enough power from energy harvesting to do all of the t h i n gs t hat m a ke Z i g B e e ZigBee. Bottom Line Energy harvesting can only become a multibillion dollar business if standards are created and interoperable equipment becomes more widely available.

We see highest volume potential for multiple energy harvesting in single devices without batteries and offering twenty year life.

For example, affordable, longlived WSN networks with much more than 10,000 nodes are sorely needed.

ENQUIRY NO. 7304

Oct/Nov 2009 | industrial automation asia 37

instrumentation & Measurement

D

ue to the continuous cost pressure on the process industry less maintenance people have to take care of much more analytical equipment in today process plants than in the past.

Therefore, analyser equipment with no need for manual adjustments, regular inspection and frequent data validation is preferred.

Despite the requested hands-off operation, the analyser availability must be high and the data quality and integrity must be ensured, at any time. As the number of measuring points in a process plant is increasing the complexity to handle complex analytical systems consisting of several analyser technologies and their related sample conditioning systems is a challenge of its own.

Here, a consistent system interface for the parameterisation and operation of complete analyser systems reduces the demand on training on the individual technologies and offers a digital interface which allows for remote observation and control via a data network.

Modern Gas Analysis Gas analytical methods based on photometry and spectrometry are well established tools to derive precise concentration data of particular gaseous compounds in complex process gas mixtures even under very harsh process or environmental conditions, in real time.

Recent innovations lead to process gas analysers designs able to operate hands-off over months without any need for maintenance or calibration. Internal validation and adjustment routines allow to check and compensate for any zero and span drifts during operation. As a result maintenance intervals of several months can be realised before there is a need for calibration with test gases or by a reference method.

38  industrial automation asia | Oct/Nov 2009

Gas Analysers:

Workers

New process gas analysers designs are able to operate hands-off over months without any need for maintenance or calibration. By Dr Michael Markus, manager business unit analysers, Sick Maihak In the following two principle examples of modern gas analysis by means of photometry and spectrometry are given.

Modular Gas Analyser The fully modular design of extractive gas analysers allows an easy way towards customised solutions for almost any application

in process gas analysis. Analysers in 19� rack mount version field housings are available in particular for applications in hazardous areas, ex-zone 1 or 2. Here, the electronics are separated by a gas-tight seal from the analysis section.

The risk of damage to the electronics caused by any corrosive or aggressive gases that are being

analysed is thus ruled out from the start. A separate case purging system can optionally be used for even more ‘cleanliness’.

System housings w ithout individual displays and keyboards offer a cost efficient option to integrate several analyser modules in a system cabinet which are parameterised and controlled via a central system controller device.

The basic 4-20 mA analogue outputs extractive gas analyser offers several binary I/Os as well as various digital data interfaces like a CAN-Bus for the link to the individual analyser modules and to I/O-modules for external communication, an Ethernet interface for the connection to an existing data network infrastructure or Modbus via a RS485 serial interface.

dioxide and nitrogen oxides are the tricky candidates to measure as they can react or become bonded with other concomitant substances while being transported through dirty filters or through extraction lines that are not optimally heated.

This results in memory effects and reduced measuring values.

The focus of new in-situ gas analysers, however, is not just emission monitoring. The analyser also takes on a key role in process gas monitoring, additionally measuring ammonia in raw and scrubbed gas.

The quick a nd precise measurements enable optimum regulation of flue gas scrubbers even when there are high levels of dust. The in-situ gas analyser fulfils high demands in terms of measuring ease, is low in maintenance and takes on very difficult measurement conditions.

For DeNOx plants in particular the NO content is used for setting the NH3 injection levels and other parameters. Measurements are taken on the raw gas side in the 1,500 ppm range and on the clear gas side in around the 100 ppm range.

H owe ve r, t he me a su r i n g

In-Situ Analysers The less maintenance the analyser technology itself needs the more the sample probe and conditioning system is the major source of cost over the lifetime of an analyser system.

Hence, a na lyser systems measuring in-situ directly in the process gas stream have an intrinsic advantage as they do not need any probing or sample conditioning system, at all. Additionally, they are mounted directly at the duct or stack and do not ask for analyser houses or shelters or heated sample lines to transport the process sample stream which reduces the total invest, significantly.

Process analysers measure in real time as any delay in the information on process relevant changes in the composition of a process gas can cause severe qua lit y or safety problems. Insitu analysers are virtually free of delay times and allow fast loop process control.

In emission monitoring sulphur Fig 1: Two examples of system housings

conditions of a DeNOx plant are not particularly helpful. High temperatures and dust load levels of over 30g/m3 are the norm. A measuring probe perfectly shaped for gas flows and with a built-in optical analysis section is inserted from one side into the duct. Just a small measuring gap in the probe is enough to record the gas concentration levels.

For applications with high dust content the measuring gap is shielded with a ceramic filter.

This keeps the measurement section free of dust and allows measurements to be taken even where dust concentration levels are extremely high. Probe-based measurement achieves response times of just a few seconds - ideal for regulating DeNOx plants.

The in-situ gas analyser utilises the gas duct as a measuring path. By using probe or cross-duct analysis a much more representative measurement is achieved than from a single spot sampling. As a result of doing away with any delays or undesired reactions during transport, the gases are analysed quickly, precisely and with no distortion.

This analysis strategy naturally also means that the analyser has to be installed right at the spot where measurements are to be taken. The in-situ gas analyser is equipped with automatic self-alignment in order to keep the analysis beam optimal on the detector even when faced with unsteady flues or changes caused by thermal movements.

Mounted up in the stack well above the process facility itself the in-situ gas analyser can often be operated without the need for explosion protection although a hazardous area is defined around the facility on the ground level.

Anyway, explosion protection can be achieved by means of overpressure protection.

Oct/Nov 2009 | industrial automation asia  39

instrumentation & Measurement

Gas supply module

Sensor module 3 eg DEFOR

Sensor module 2 eg OXOR-P

Sensor module 1 eg THERMOR s module

CANopen

Power supply unit

I/O module

SCU (System Control Unit)

Fig 2: The modular concept

UV Spectrometry The signal analysis is done across a broad spectral range in the UV region. Using the DOAS principle (differential optical absorption spectroscopy), the optimised analysis procedure seeks out in each case the best spectral lines for the measurement range and components concerned. This achieves a very high degree of measuring precision and signal dynamics.

It is possible to measure both small and large measurements extremely accurately using the identical device. In this way the in-situ gas analyser can also record higher measured values, eg in the event of a purification facility failing.

The device is equipped with a maximum of four gas components and can optionally also measure temperature and pressure. All in all, 16 outputs can be serviced.

T he re qu ire d me a su rement ranges for emission components can be mapped and at the same time other, differently scaled ranges can be used for control purposes.

This in-situ gas analyser is the first UV in-situ analyser for SO2 and NO to have been certified to be fully compliant with the Eu rop e a n qua l it y dire c t ive EN15267-3. The key factor here is that for the regularly required QAL3 tests the analyser needs no test gas. An integrated filter wheel automatically tests drift and function.

The built-in Ethernet interface of the in-situ gas analyser enables a service engineer to check the device from the desktop PC in his office or from any other Laptop PC in the corporate network or via modem and portal.

All of the most important data, status reports and measurements can be accessed over the network link. Technical support by means of remote diagnosis and the new modular product concept for fast on-site servicing are two genuine innovations that bring major customer benefits.

ENQUIRY NO. 7401 Detector Calibration unit

Sick:

UV lamp

Filter wheels

Extractive UV Gas Analyser

S

ick’s Defor utilises gases’ optical characteristics within the ultraviolet spectral range and analyses up to three measured components like SO2, NO2, CL2, NH3, CS2, H2S und COS, simultaneously, even in very small ranges. There are no cross sensitivities in respect of CO2 or H2O.

40  industrial automation asia | Oct/Nov 2009

It utilises an electrodeless discharge lamp which emits both NO-specific and other wide-band rays. Using interference and gas filters, optimum measurement and comparison wavelengths related to the gas component are then selected inside the thermostatic filter wheel

Detector Measuring cuvette

Reference cuvette Filter enclosure

Collimator lense Beam splitter

unit. These rays are directed onwards to detectors via the analysis and reference cells.

A quotient is formed per detector from the obtained signal levels and these are then compared with each

Mirror

other. This double quotient formation compensates not only for any proportional signal drifts, but also any symmetric drifts.

ENQUIRY NO. 7402

ENQUIRY NO. 068

SECTOR SPOTLIGHT

PROCESS

SAFETY In Specialty Chemicals New standards offer more choices for integrating safety and process control. By Art P Pietrzyk, Rockwell Automation

42

industrial automation asia | Oct/Nov 2009

he specia lty chemica l industry is facing a number of difficult challenges, including increasingly stringent safety and compliance mandates, higher energy and feedstock prices, and aging plants and equipment – all intensified by global competition.

Compounding these challenges is the expanding breadth of specia lt y chemica l product categories, forcing manufacturers to dedicate major resources and continuously innovate to maintain market share and capitalise on new opportunities.

Despite the size of the industry and the increase in worldwide

A spill of a toxic agent or explosion could be hazardous to a population within a plant or the surrounding area. One growing area of focus in recent years is the critical value of safety in protecting people, and helping safeguard the environment and plant assets, as well as reducing lifecycle costs.

This article explores how changes in industry standards and technology developments are expanding how safety systems are applied in specialty chemical applications. It also examines the operational and competitive advantages driving the trend toward separate yet interoperable safety

demand for all types of specialty chemicals, margins must be managed closely due to rising costs, more demanding customers, and the fact that all products – no matter how innovative – eventually go offpatent and face stiff competition.

While operating a chemical plant is tough business, opportunities exist for companies to optimise their investments and improve both productivity and their financial performance.

and process control platforms with common development tools. These benefits include reduced life cycle costs, expanded access to process data and improved plant-wide integration.

Value Of Safety Risks prevail wherever people store, process or handle hazardous or toxic materials. In the specialty chemical industry, these risks are compounded because the hazard has the potential to impact numerous people.

Changing Requirements Safety is not a new issue for specialty chemical manufacturers, but industry standards, such as IEC 61511, include specific performance and life-cycle criteria that quantify system reliability through failure rates. These failure rates are based on three key criteria: fault detection, fault tolerance and PFDd (Probability of Failure on Demand), which qua ntifie s da ngerous undetected failures.

Risk assessment processes defined within these standards

typically take a life-cycle approach in clarifying how to implement an effective process to identify hazards. This is where the HAZOP (Hazard and Operability) analysis often plays an important role in the process design.

Central to the HAZOP is assessing the risk associated with the hazard.

Unlike machinery assessments, risk assessments in specialty chemical applications employ a vaster, more encompassing focus due to the potential for accidents to impact a much wider area, such as an entire facility or community.

Performed by a multidisciplinary team, the HAZOP analysis identifies

Until recently, users had little choice other than to use separate, independent and diverse systems for control and safety

hazards and operability problems, and investigates and considers how the plant might deviate from the design intent. This systematic, highly structured assessment relies on HAZOP guide words and team brainstorming to generate a comprehensive review and help make sure proper safeguards against accidents are in place.

A risk analysis is integral to this process to quantify the level of risk in terms of severity of consequence, frequenc y of e x posure a nd probability of avoidance. The risk Oct/Nov 2009 | industrial automation asia 43

sector spotlight

assessment quantifies the risk into one of four possible Safety Integrity Levels (SILs). The designated SIL represents the amount of safety that must be available to mitigate the risk.

Once the different hazards have been identified, the next step is to determine a way to help reduce the risk within those hazards to a tolerable level. A variety of ways exist to do this as outlined in standard IEC 61511.

For example, one effective way to reduce risk is through Layers of Protection Analysis (LOPA). The method starts with data developed in the HAZOP and accounts for each identified hazard by documenting the initiating cause and the protection layers that prevent or mitigate the hazard.

T h e L O PA m e t h o d o l o g y allows the determination of the appropriate SIL for the Safety Instrumented Function (SIF).

Safety Control Challenges Specialty chemical manufacturers employ many types of control systems that continuously manage parameters, such as temperature, flow, pressure, weight and viscosity.

Plants need to keep some processes going for practical and financial reasons.

For example, shutting down a distillation column could cause the liquid to fall to the bottom and solidify, damaging expensive process equipment. Therefore, critical devices – such as exhaust fans, pumps, valves and motors – must remain on if the Basic Process Control System (BPCS) fails.

Since processes can create hazardous situations when they are out of control, the BPCS – historically a DCS, but today possibly a Process Automation System (PAS) – may not be able to keep the process under control in the event of a failure. This is where the Safety Instrumented System 44 industrial automation asia | Oct/Nov 2009

(SIS) comes into play.

The goal of the SIS is to maintain control, and if necessary, shut down the process in an orderly way that protects the people, equipment, and plant, as well as helps minimise production losses.

Common types of safety systems include emergency shutdown, fire and gas monitoring, critical process control, burner management, and turbo machinery control.

Since the goal is to maintain pro ce s s co nt rol , m a x i mu m availability is a core requirement of safety instrumented systems. High availability from a process controls perspective simply means that the control system will be available to perform its function. This is regardless of changing conditions or operational malfunctions.

The system is designed to tolerate failures, allow changes, repairs and replacements without significantly affecting the mission.

The designer must accept the fact that components and system might fail, and design the application around this assumption.

However, even the most robust system might not be the most available. To achieve maximum availability, a system must be easier

The desire for better information sharing and coordination is driving specialty chemical companies toward more integrated platforms

to troubleshoot, modify and repair during the life of its mission, which could exceed a decade or more.

Additional features that can keep the control system on its high availability mission, such as statebased control and self-learning diagnostic routines, improve the controller’s ability to detect, annunciate and describe problems within the process.

For many applications, the ability to maintain and revise the system without shutting down offers an acceptable level of availability, especially if the change or repair can be made quickly.

Cr it ic a l pro ce s s co nt rol applications are those in which the process must be maintained during a fault state to help minimise the potential for loss of life, damage to the environment or loss of production.

Triple Modular Redundant ( T M R) te ch nolog y of te n is employed to achieve the highest level of fault tolerance and safety.

These systems are designed with three parallel systems running in a redundant design. All three systems process the input information and vote to affect a result.

That is, a two-out-of-three vote is required to effect a change or stop a process. The system is capable of running in a reduced safety state if under a faulted condition and must be repaired, or if the process must be systematically shutdown.

The redundancy requirements encompass more than the logic solver. They include all of the elements that make up the SIS including input devices (sensors, switches, instrumentation) and output devices (pump motors, valves and other actuators).

All must be selected to meet the required SIL level for the safety loop or function Safety instrumented system must include measures that can detect a failure of one of the critical control elements.

Measures such as redundancy, self-monitoring, crosschecking, testing and diagnostics typically are employed in the SIS. More Control Choices The primary function of a BPCS is to hold specific process variables and parameters to predetermined levels in a dynamic environment.

An SIS, on the other hand, is static, waiting to take action to bring the process to a safe state when the process is out of control and the BPCS is unable to do so.

As a result, manufacturers traditionally implemented BPCS and SIS as separate systems, with separate operator interfaces, eng ineering work stations, configuration tools, data and event historians, and network communications. Life-cycle costs, such as spare parts, support, training, maintenance, and service usually are higher with this approach.

Never theless, ma ny good reasons remain to put safety and control functions in different controllers. They include: • Independent failures: minimising the risk of simultaneous failure of a BPCS along with the SIS • Physical separation: preventing changes in a BPCS from causing any change or corruption in the associated SIS • Different requirements: an SIS is normally called on only in the event the BPCS fails.

An SIS needs to have higher levels of security and typically doesn’t change much once it’s implemented, unlike a BPCS, which is usually designed for accommodating changes For years, DCSs have been the staple platform for process control, delivering powerful, reliable service. But as these systems age, manufacturers are faced with the arduous task of maintaining proprietary, dedicated hardware

and software platforms. These systems lack multi-disciplined control capabilities.

To m e e t e f f i c i e n c y a n d profitability goals, companies need systems that can help meet the diverse control applications within their facilities, including sequence, process, batch and drive control, along with the ability to integrate with information systems.

Until recently, users had little choice other than to use separate, independent and diverse systems for control and safety. Some users even required the BPCS and SIS be supplied from different vendors.

Today, however, users are finding a number of business and financial reasons for using more integrated platforms for safety and process control in their plants.

For example, PASs offer a more cost-effective solution because of their ability to provide a common infrastructure with common bases or tag bases, alarms and events, networks, software and development tools. This helps simplify asset management and reduce operation, maintenance and training costs.

Specialty chemical manufacturers today need improved information flow across the enterprise, with the ultimate goal of controlling or reducing lifecycle costs. Perhaps the biggest advantage of integrating the process control platform is the potential for expanded information sharing capabilities between BPCS and SIS. The ability to leverage the data streaming from the plant floor is increasingly critical in today’s competitive environment – particularly in the specialty chemical sector where production must be tightly integrated as part of the supply chain so companies can be as efficient and productive as possible.

One growing area of focus in recent years is the critical value of safety in protecting people

The Technology Forefront Advances in control technology now allow companies to combine the reliability advantages of DCS technology and safety control without the historic limitations tied to each. Some BPCS and SIS suppliers offer common systems for both functions that incorporate the same configuration tools, programming software and components.

The key is to help make sure the two systems are functionally separated, but share common hardware, software, and networks.

This allows users to achieve the operational benefits of a common platform while meeting the functional safety requirement for separation.

The desire for better information sharing and coordination is driving specialty chemical companies toward more integrated platforms.

But not all control platforms are created equal. Likewise, not all specialty chemical companies are at the same stage in their control system lifecycles where one solution will meet their diverse needs.

Still, it’s important that the BPCS and SIS you deploy offer the necessary attributes to contribute to a more cost-efficient, informationenabled environment.

ENQUIRY NO. 7501 Oct/Nov 2009 | industrial automation asia 45

ENERGY

Green Buildings:

THE

PROTECTING Environment

A

green building is a structure that is designed, constructed, renovated, operated, or reused based on a philosophy of ecological and resource efficiency (energy, water, and materials), while reducing overall impact to the environment and protecting occupant health, throughout the building’s lifecycle.

According to the United Nations Population Fund, more than half the world’s population now live in cities, with five billion urban dwellers by 2030.

Most of the new urban growth will occur in smaller towns and cities, which have fewer resources to respond to the magnitude of the change. Seen in this perspective, green buildings have become popular in recent years due to heightened environmental 46

industrial automation asia | Oct/Nov 2009

consciousness amid rapid global urbanisation.

High Energy Consumption Buildings in the US and European Union used 40 percent of the total energy consumed, according to various estimates. Of the total amount of water consumed per day in the United States, 38 percent of the total amount of carbon dioxide and 12.2 percent can be attributed to buildings.

According to the Asia Business Council (ABC), buildings account for 30 percent of the world’s total energy consumption and a similar percentage of the world’s greenhouse gas emissions. Asia’s buildings share of global energy consumption doubled in 30 years, but more than half of all future growth will occur in China and India.

With the rising tide of environmentalism, green buildings will be the norm in eco-cities of the future. By Augustine Quek

The ABC also estimates that green buildings can reduce 1.8 billion tonnes of CO2 per year, close to three times the amount scheduled for reduction under the Kyoto Protocol. Considering these statistics, reducing the amount of natural resources buildings consume and the amount of pollution given off is seen as crucial for future sustainability.

Green building is a concept that incorporates a wide spectrum of solutions, best-practices and technologies. Green building brings together a vast array of practices and techniques to reduce and ultimately eliminate the impacts of buildings on the environment and human health. It can use renewable energy technologies such as solar photovoltaics and wind turbines, or less sophisticated techniques such

Green Software Much of the work involved in realising a green building is during the design and planning stage, where the various green components are integrated without conflict and functioning smoothly after construction is completed.

Dedicated software is available for specia lised modeling of green building designs. Building information modeling (BIM) is a process to create and analyse design alternatives and better predict performance in terms of energy use, water use, daylighting, and other key factors. Visualisation of the model provides insight into the effect of design decisions on the actual experience of the space in terms of light and thermal comfort.

The United States Department of Energy (DOE) has a webpage dedicated to green building modelling tools. US DOE’s Energy Efficiency and Renewable Energy division has a building software tools directory of building analysis software, with scores of programs covering everything from wholebuilding analysis to fenestration, life-cycle analysis, hydronic heating, and multi-building analysis.

Automating Green Buildings Simulating a building before it’s built is only the beginning. The next crucial step is to ensure that its usage, operation and maintenance have minimal environmental impact. While many different components are involved in a green building, one tool that can help ensure that a building remains green after it is built is a building automation system (BAS).

A BAS automatically controls systems within a facility that use energy and/or affect the indoor environment. When properly integrated into a facility, a BAS can help to optimise energy,

operations and indoor comfort over the entire lifetime of the building. Besides minimising the building’s environmental impact, such benefits can also minimise operation and maintenance costs and improves occupants’ comfort and productivity.

A typical BAS comprises three major components: workstations, super v isor y controllers and application controllers. The workstations function as a control centre, which can monitor and intervene in the facility operations.

The supervisory controllers communicate to the field devices and handle such actions as interlocking, scheduling, trending (obtaining data on energy use throughout the building, etc) and other forms of programmed functions, while the application controllers, also called device level controllers, control the functions of the various systems throughout the building based on input from the supervisory controllers.

These components require very little space and can typically be integrated into any building design without any special design requirements.

Examples of BAS include BACnet, a data communication protocol for building automation and control networks, and other BAS from

Jason Antony, Canada

as plants and trees on green roofs to beautify and cool buildings.

Energy efficient light bulbs are one way of lowering energy consumption

automation companies such as Honeywell, Rockwell, Siemens, Advantech etc.

BACnet was originally developed by the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) in 1987. It is an open standard protocol that can easily be extended to new devices and has now become an American national standard, a European standard, and an ISO global standard. Many vendors’ systems can now be integrated into BACnet in a green building automation system.

Green vs Energy Efficiency A common misconception is that energy efficient buildings are also green buildings. While energy efficiency is an integral part of a sustainable building, other methods of reducing t he environmental impacts such gardens, rainwater

Case Study 1:

Poh Ern Shih Temple

P

oh Ern Shih, a 55 year old temple in Singapore, uses at least three forms of renewable energy, solar photovoltaic, solar thermal, and wind.

Its solar photovoltaics, a combination of crystalline, amorphous and thin-film, spread across various roofs, produces a combined power of

15 megawatts (MW) of electricity annually. Seven solar water tanks also provide hot water at 70°C for showering and cooking.

It also has plans to install micro-hydro generators to capture energy from the flow of water from 25 metres of elevation.

In addition, passive lighting is used in the

temple’s lower levels during the day through solartubes that contains magnifying mirrors. Other features include treatment of rainwater from its many storage tanks through a reverse-osmosis and ultraviolet system, and recycling of urine as fertilisers for its butterfly gardens.

ENQUIRY NO. 7601

Oct/Nov 2009 | industrial automation asia 47

Rainer Berg, Germany

energy

Green buildings can use technologies such as solar photovoltaics

Laura Leavell, US

harvesting and waste recycling are also important.

Worldwide, about two dozen countries have already had green building assessment standards, such as the LEED in the US, Green Star in Australia and Green Mark in Singapore.

According to Dr Ken Yeang, a Malaysian architect and ecologist, a green building is not just about eco-technology or accreditation.

Green buildings need to integrate human activities with the natural environment in a seamless and benign way. His ideal building is modelled on the dynamics of nature, generating energy from the sun and wind, be increasingly efficient with energy use and support an increasingly diverse ecological system.

One of Yeang’s work, Solaris, a 15-storey multi-tenanted facility in Singapore, is a sustainable building.

A solar shaft brings light into the building, with a day-lighted grand

A survey by the World Business Council for Sustainable Development finds that green costs are overestimated by 300 percent 48 industrial automation asia | Oct/Nov 2009

atrium and sun shading devices on the exterior. Its continuous spiraling landscape includes gardens that start from the ground floor and end in roof gardens, reducing solar gain and improving its rainwater harvesting. Natural ventilation, waste separation and recycling and a BAS system are also incorporated.

According to The Straits Times,

only one percent of all buildings in Singapore are currently green buildings. Of these, only 31 out of 307 rated buildings achieved a platinum rating, the highest possible Green Mark category. One possible reason is the issue of costs.

A recent survey by the World Business Council for Sustainable Development finds that green costs are overestimated by 300 percent, as key players in real estate and construction estimate the additional cost at 17 percent above conventional construction, more than triple the true average cost difference of about five percent.

Therefore, the Building and Construction Authority in Singapore has released a slew of initiatives this year to boost the proportion of green buildings in Singapore to 80 percent by 2030.

ENQUIRY NO. 7602

Case Study 2:

PTM Green Energy Office Building

A

good example of a green building that uses passive and active energy efficient elements and renewable energy is the PTM Green Energy Office Building (GEO) in Bandar Baru Bangi, Selangor, Malaysia. Its energy consumption of 65 kWh/m2year is much lower than a typical conventional office building in Kuala Lumpur of 250 to 300 kWh/m2year.

The design of the building includes double glazing, twin-planed glass windows installed on facade, facing north and south. These windows filter heat from both infrared

and ultraviolet rays from the sun radiation before entering the building interior, providing natural light while reducing heat.

The building’s cooling system is a combination of radiant cooling and air convection system. The radiant cooling comes from the low temperatures of the floor slabs, which are cooled by the air at night.

Ice is also accumulated at night in ice storage tanks. During the day, these provide cooling sources, distributed by the building’s control system to the radiant cooling and air convection system respectively.

The Building Integrated Photovoltaic (BIPV) system provides almost 50 percent of the building’s electrical needs. Energy efficient T5 tube electrical lighting was installed for the entire building.

Energy efficient office equipment is used such as shared centralised printers, wireless network and energy efficient centralised servers.

The entire building is controlled with a Building Energy Management System where all building’s system operation is controlled automatically.

ENQUIRY NO. 7603

Shedding Light On The Building Illumination Market APAC consumers consider energy efficiency and long life as important considerations when buying light bulbs.

By Tonya Fowler, global director, customer research team, Frost & Sullivan Frost & Sullivan’s end-user study, Voice of the Customer: Perceptions and Behaviors toward Building Illumination Markets research measures APAC consumers’ brand awareness, brand perceptions, current usage, consumers’ willingness to pay for building illumination products, and features deemed important in building illumination/light bulb products.

This research surveyed building illumination owners/consumers within Australia, Indonesia, Japan, Malaysia, Singapore, South Korea, and Thailand.

A lthough this resea rch surveyed air conditioner owners withinsevencountriesoftheAPAC region, many manufacturers of air conditioners distribute across APAC and beyond, whilst some do not distribute their products within all surveyed countries. Some brands heavily influence the entire region findings by individual country awareness, preferences and ownership results.

brands known and preferred respectively. Other top brands like Panasonic, GE and Osram are known, preferred, and owned according to country analysis, though not necessarily across the entire APAC region.

Overall, unaided awareness is low among all building illumination product brands surveyed although a preferred communication mode is through in store displays, which allow

Brand Awareness The most commonly known and owned building illumination brand in the APAC region is Philips. However, in Japan and South Korea, Panasonic and Osram are

What Consumers Want Amongst important building illumination features surveyed in this study included energy efficiency, brightness, long life, price, availability and brand name.

According to the survey, consumers consider the various

building illumination features surveyed similarly, as most features are perceived as being at least ‘somewhat important’.

Energy efficiency and long life are rated most important.

It is noteworthy that APAC consumers consider energy efficiency and long life as i mp or ta nt con side rat ion s as the basic function of light bulbs – to provide light. This indicates that APAC consumers are environmentally and/or cost conscious. Conversely, brand name is of little importance to most consumers.

Overall, it appears most APAC consumers have transitioned from incandescent light bulbs to more energy efficient fluorescent light bulbs (fluorescent tubes/ bulbs and compact fluorescents, known as CFL bulbs). However, fluorescent tubes/bulbs are more popular than CFL bulbs.

Most APAC consumers are

“It is interesting that in our other APAC consumer research of various other inhome use products such as airconditioners and air purifiers, energy efficiency emerges as the top feature sought by consumers.” Tonya Fowler consumers to see the effects of building illumination products first-hand.

willing to pay up to 10 percent extra for energy efficient light bulbs. Specifically, the majority of consumers sur veyed in Indonesia, Malaysia, and South Korea with the exception of Thailand, are willing to pay extra for energy efficient light bulbs.

Beyond 10 percent however, significantly fewer consumers appear willing to commit.

ENQUIRY NO. 7604

Oct/Nov 2009 | industrial automation asia 49

eNergy

Building

Towards A Sustainable

Future

All new Siemens buildings, such as The Siemens Center in Beijing, China, will consume 25 percent less energy than local standards

Christoph Conrad 50

industrial automation asia | Oct/Nov 2009

Christoph Conrad, senior VP, Building Life Cycle Management, Building Technologies, Sector Industry, Siemens tells IAA why maximising energy efficiency in buildings is so important.

By Derek Rodriguez

IAA: What are the major factors that contribute to energy wastage in buildings?

Christoph Conrad: The problem starts during the design and build phase. In most cases, life-cycle costs are not a consideration during the procurement process.

Investing in an efficient heating and lighting system right from the beginning might be more expensive. But here, we are talking about a 3-5 year ROI phase, and a reduced energy consumption of up to 40 percent, compared to using ‘normal’ heating and lighting.

The amount of energy consumed by any equipment or system is very much dependent on its operation, and the interaction between different components within the building. In order to make the right decisions on how to counteract the energy wastage in a building, it is essential to first have a full transparency of the energy flow within the building. This is the basefloor to optimise the energy efficiency in a building.

IAA: What are some of the ways to maximise energy efficiency in buildings? Is energy efficiency more dependent on the types of instruments/lights/ products used or is it more than that?

CC: To maximise energy efficiency in buildings, it is absolutely necessary to have a building life-cycle cost consideration at the start of the building project, instead of trying to minimise the initial investment.

In addition, to reach maximum energy efficiency, it is a must to create an ongoing transparency of monitoring the building. Based on that we can decide if energy efficient equipment (eg new lighting systems requires up to 80 percent less energy) ought to be installed, or if a total building energy management process is required.

To have a green and sustainable building concept, we need more than just green products. We can liken this to an orchestra – where the key element is not just the performance of a single musician. It is the integration and collaboration of all the musicians, guided by an excellent conductor. This is how we perceive building automation to be and why we invest a lot in the implementation of ‘total building solutions’ to optimise the building behaviour.

IAA: How much savings, in terms of energy and money, can customers expect in employing energy efficient techniques?

CC: This depends of course on status quo, age, technical equipment of the building, and the possible investment and efficiency approach. Additional considerations are the operator qualification, user motivation and the intended energy concept.

In some cases, we have seen savings of up to 40 percent. The average value is in the range of 25 percent.

In some cases we have been able to optimise the energy consumption in a 3 year old building by 30 percent, just by adjusting the installed equipment.

In total we have completed more than 1,500 energy efficiency projects worldwide over the past 10 years and helped our customers achieve close to €2 billion (US$2.9 billion) in energy savings. Worldwide, we have significantly reduced energy consumption and CO2 for hospitals, schools, public facilities, multi-unit housing complexes, etc.

IAA: Considering the cost of your services and other costs, what is the estimated time frame that customers can recoup their investment in?

CC: From an economic standpoint, it usually depends on the cost of energy from the original source such as the main power grid, coal, oil, etc. If the original cost is

very high, then the economics of green technologies may be more appealing.

On the other hand, from a climate protection standpoint, using green technologies is sometimes dependent on the desire of the private sector to model a sound environmental policy versus public sector organisations that need to adhere to certain legislation or mandate to reduce the carbon footprint of their facilities.

IAA: Is it difficult to convince someone of the need to be energy efficient, especially in Asia where customers might not be receptive to the idea?

CC: Our clients all have concerns and focus on ecological issues regardless of country of origin.

It is of course always a question of investment and payback. That is why we offer from the beginning a total life-cycle-cost consideration and see ourselves as a partner to the customer in this process.

Some countries have more strict mandates or legislation regarding CO2 emissions and energy efficiency while others provide the framework for their corporate citizens within which to operate.

IAA: What other barriers are there in employing energy efficiency?

CC: Regardless of the economic conditions, we believe customers and the general public continue to be concerned about the environment and climate change. And in general, many businesses will weigh the economics of doing a green or energy efficiency project with the return on their investment.

But there are also many corporations committed to doing whatever is necessary to minimise their carbon footprint, reduce energy consumption, and lessen the impact to the environment. And we are convinced that today’s technical solutions available can solve the climate challenges to a large extent.

Assisted by Siemens, the Shanghai Yangpu government building has achieved a CO2 emission reduction of close to 600 tonnes a year

Oct/Nov 2009 | industrial automation asia 51

energy

IAA: How can large technology companies such as Siemens promote awareness for the need to save energy, not just because it makes sense economically, but also to be more environmentally conscious?

CC: Innovation is the strongest lever to increase energy efficiency and reduce greenhouse gas emissions. Many of the technologies needed are already available today.

And the best way of promotion is always to show proof that they work.

Siemens launched a ‘Green Building Initiative’ which ensures that all new Siemens buildings will consume 25 percent less energy than local standards, and reduce energy-consumption by 20 percent reduction by 2011.

The long term goal is to develop a zero-energy standard for our buildings in the future.

IAA: Which countries will the CoC in Singapore cater to?

CC: The CoC in Singapore is an expertise hub and offers professional consulting and implementation support for energy efficiency in buildings and gives guidance and support to local Siemens representatives dealing with energy efficiency. It is closely interlinked with all CoCs worldwide to ensure top quality for our global customers.

From the Singapore hub we will support South Korea, China, Taiwan, Australia, Hong Kong and India.

The CoC does not replace the need of a local presence in the country. The CoC will provide trainings and special know-how to guarantee and to expand this know-how in the countries it serves.

IAA: Does opening the CoC signal an intent to get more of a foothold in the region?

CC: It is the responsibility of an innovative company like Siemens to be even more attractive to its customers in Asia Pacific due to significantly enhanced position in the field of outstanding customer support.

The CoC is a commitment of our long term investment in the field of energy expertise for buildings in Asia Pacific. It will continue to evolve and expand, in close alignment with our customer needs.

IAA: What, in your opinion, is the energy technology that is the most promising at the moment?

CC: The future in Building Automation belongs to Smart Buildings. It will be a challenge to consider the building as an active energy component within the total concept of smart production, smart grid and smart consumer.

Growing customer demands for open, interoperable subsystems, along with widely available, high-speed information-technology networks, have fueled the transformation of the buildingautomation sector.

And in the face of the mega trends of demographic change and urbanisation, an intelligent energy management system in a building will play a very central role in the management of new and existing cities.

ENQUIRY NO. 7605

Siemens Sets Up Centre Of Competence Singapore: Siemens has unveiled a Centre of Competence (CoC) Asia Pacific for Building Life Cycle Management. Based in Singapore, the CoC provides expertise to monitor and navigate through the entire life-cycle of buildings to help building owners to maximise the performance, efficiency and sustainability of buildings.

The team of energy experts at the CoC will provide coaching and support for the promotion and implementation of energy efficiency. They will help building owners maximise efficiency for all facilities

52 industrial automation asia | Oct/Nov 2009

by focusing on entire building life cycle, from initial design and build, through operate and maintain, to renew and revitalise.

A key feature of the CoC is its Advantage Operational Center (AOC), a remote energy monitoring and analysis facility where energy data of multiple building sites are continuously collected for expert studies and reviews. The first centre of its sort in Asia Pacific, the AOC runs on a web-based platform that allows for energy usage and building automation system information to be conveniently

and securely accessed and analysed.

With the information collected, the AOC makes recommendations to customers to help them maximise their energy savings. Following the analysis and recommendations, the CoC can support customers in the implementation of energy saving programs. The team of energy experts can even structure appropriate financing schemes for customers’ energy saving projects. The comprehensive portfolio of the CoC helps facilities achieve maximum efficiency.

ENQUIRY NO. 7606 ENQUIRY NO. 7603

ENQUIRY NO. 052

features

W

hen Christopher Columbus made his first voya ge to the new world in 1492, he was travelling in a carrack, a sailing ship. A lot has changed since then. In shipbuilding, metal, especially steel has overtaken wood as the main material for construction.

The modern shipping industry is large. This industry involves huge capital, wide workforce and technology. The process of shipbuilding is also lengthy in terms of time taken and there are many other ancillary industries associated with shipbuilding as suppliers.

As such, from the technology point of view, modern shipbuilding has adopted new techniques and technology to make the process a m o re e f f ic ie nt o ne . T he industry also saw most activities transferred to Asia with South Korea emerging as the powerhouse of shipbuilding.

Shipbuilding Capital According to Korea Times, South Korea has retained its number one position in shipbuilding nation in terms of new orders, order backlogs and volume of vessels built in 2008.

Home to seven of the world’s top 10 shipyards, some 17.5 million compensated gross tonnes in new orders were won last year, accounting for 41.1 percent of all global new orders. Chinese shipbuilders took the second spot with orders totalling 14.9 million Compensated Gross Tonnes (CGTs) last year, outpacing Japanese rivals, which won a combined 4.89 million CGTs. Clarkson, a London-based market researcher said that South Korean shipbuilders’ combined order backlogs totalled 67.7 million CGTs, making up nearly 35.8 percent of 189.2 million CGTs in global backlogs. China followed with 60.73 million CGTs.

Staying Shipbuilding:

Afloat Metalworking processes are a big part of shipbuilding as the industry undergoes the process of renewal. By Joson Ng

54 industrial automation asia | Oct/Nov 2009

The Work To Sea Worthiness Like anywhere else in the world, with metal as the chief building material for shipbuilding, the relationship between metalworking and shipbuilding is a very close-knit one. Not just that, improvements in metalworking also creates benefit in shipbuilding.

For instance, weld seam facing tools can reduce or eliminate the need for manual grinding of weld reinforcements on the DDG 1000 class of ships (military vessel).

The manual weld removal is slow, which increases shipbuilding costs, and the repetitive nature of hand grinding causes frequent injuries (eg, carpal tunnel, eye, back) and costly medical expenses.

The cost savings from using weld seam facing technology for removal of butt welds alone on DDG 1000 is estimated at US$750,000 per hull.

T he prepro duct ion tools remove the weld automatically at a minimum rate of 20 feet per hour

Michael Broxton, San Francisco, USA

The relationship between metalworking and shipbuilding is a very close-knit one

In addition, stress concentrations are studied using a finite element analysis model to complement structural analysis.

Whether is it design, assembly, pre-outfitting and other shipbuilding processes, metalworking has a stake every step of the way.

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ENQUIRY NO. 7701

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is an important step before commissioning a ship.

These simulations incorporate pressures causes by waves and the movement of the ship as well as the hydrostatic pressure applied to the ship. Climatic conditions are taken into considerations as well.

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versus the current rate of three feet per hour. The tool is capable of removing the majority of weld reinforcement height with minimal or no further hand grinding.

Apart from grinding, tube bending is another process found in shipbuilding. With tubes in today’s shipyard ranging up to 220mm in diameter and 12mm in wall thickness, a variety of large CNC bending machines are required to support the demand of the ship building industry.

Bending tubes with thick wall bending requires applying pressures in tones down the column of the pipe while bending.

This is done in order to prevent unnecessary wall thinning of the pipe wall on the various types of material used.

Though machining is heavily featured in the construction of marine engines and shipbuilding, metrology is also a big part of that industry. Structural analysis

Oct/Nov 2009 | industrial automation asia  55

features

Guaranteeing

Success

With Standardisation

FDI combines the advantages and tried-and-tested concepts of both EDDL and FDT. By Daniel Grossmann, research engineer, ABB Corporate Research and Achim Laubenstein, manager, fieldbus standardisation, ABB Process Automation Division

56  industrial automation asia | Oct/Nov 2009

he FDI concept is based on the client-server architecture model. In an architecture of this kind, a server provides services that various clients (usually distributed) access. A popular client-server architecture is the Internet, for example.

I n t he F D I c l ie nt- se r ve r architecture, an FDI server provides access to the ‘information model’.

The information model maps the communication topology of the automation system by representing the entire communication infrastructure and the field devices as objects. In concrete terms, this means that the data, functions and user interface of field devices are mapped in the information model.

FDI clients then access the information model via the FDI server in order to load the user interface of the field device and display it on the client side, for example. If the user now uses the user interface to change parameters of the field device, the client transfers these back to the information model.

In addition, FDI clients can also access the device parameters in the information model without a device-specific user interface (eg for condition monitoring).

The data, functions and user interfaces of the FDI server that have to be represented in the information model are defined by the device manufacturer by means of the FDI device package with the following contents: Device definition, business logic, user interface descriptions and user interface plug-ins. The device definition describes the field device data and the internal structure (eg blocks). The business logic primarily ensures that the device definition remains consistent. User interface descriptions and user interface plug-ins define the field device user interfaces.

Device definition, business logic and user interface description are based on EDDL (IEC 61804-3). The

user interface plug-in offers the advantages of freely-programmable user interfaces familiar from FDT/ DTMs. Other FDT concepts that are being seen in FDI are nested communication, ie the open integration of gateways, and the integration of communication drivers over communication servers.

Ultimately, of course, what counts is the advantages for device manufacturers, control system manufacturers and, in particular, customers.

For device manufacturers, FDI reduces effort and saves costs because in future, only one FDI device package with clearly delimited protocol-specific parts will have to be created, instead of the current three EDDs and three DTMs. Another advantage is the scalability of the device package.

For control system manufacturers, the client-server architecture simplifies the use of device data and functions in powerful, distributed control systems. In addition, transparent access to device data and functions facilitates the integration of other applications (eg connection of MES).

For the customer, the main benefit of FDI lies in the standardised integration of field devices through a future-proof standard.

One basic prerequisite for this is the unrestricted interoperability of device packages from a wide variety of device manufacturers with FDI systems from a wide variety of control system manufacturers.

One Standard, Multiple Implementations The description language EDDL is specified in full in IEC 618043. Because of the different c o m m u n i c a t i o n p r o to c o l s , FF, HART and Profibus, there are necessarily a few protocolspecific language elements. In the specification, this fact is reflected in the EDDL profiles. These define which language elements of EDDL

Fig. 1: The FDI concept

FDI Client

OPC UA FDI Server Topology Network

Device Package Device Definition

Business Logic

User Interface Description

User Interface plugin

are permitted for a device with a specific type of communication.

While some of the differences are indeed due to the differences in the protocol features, far more are due to the history of the language in the various fieldbus organisations. This leads to the problem of a device manufacturer being unable to write a protocol-independent ‘core EDD’ for a device type because • The language constructs are mapped differently in the profiles for FF, HART and Profibus • The profiles are not implemented in full by the various hosts The FDI team has looked into this point and will ensure that EDDL mapping for FDI is fully standardised apart from the necessary communication-specific factors.

Further expense is generated as a result of the different ways the fieldbus organisations have implemented EDDL over time.

There are different binary formats and each of the organisations maintains its own tools and components for creating, testing and processing EDDs (reference interpreter). T he tools a nd components vary significantly in their structure, functional scope and quality. Additional tools are needed for FDT implementation.

From a technical point of view,

Device Device Information Model

Server Engine

there is no need for this variety.

However, it is clear that more costs than necessary are generated (Fig 2).

If we were to continue with this approach, the implementation of FDI would generate expense in each of the three fieldbus organisations in order to carry out the same enhancements for the tools and components. The resulting costs are indirectly paid for by the members of the organisation, ie the manufacturers.

For the host manufacturers, additional expense arises for the integration and maintenance of three interpreter components.

Integration is made more difficult because the implementation concepts and the scopes of delivery in the fieldbus organisations differ considerably. Each interpreter component has its own development cycle. This needlessly increases the complexity on the host side and is a potential source of interoperability problems.

Additional expense arises for the device manufacturers because they must create different EDDs for the same application depending on the particular fieldbus standard. For this, they use different development and test tools. Finally, host-specific modifications are also required.

All variants need to be maintained over many years.

Oct/Nov 2009 | industrial automation asia 57

FEATURES

Customer dema nds for a standardised, low-cost solution and good interoperability can scarcely be met because of the variety of EDDL implementat i o n s . P ro b l e m s i n d e v i ce integration are ultimately an obstacle to the use of fieldbus technology.

T he i nt ro duc t ion of F D I offers the unique opportunity to increase the acceptance of FDI in particular and the fieldbus in general through the standardisation of EDDL and its implementation.

Genuine Standardisation ‘G enuine’ sta nda rdisat ion requires that the FDI standard is fundamentally independent of communication protocols, but can be adapted for communication protocols. It should be possible for a device manufacturer to create a device package per device type without host- specific or interpreterspecific modifications.

A standardised workflow and standardised tools and components for the implementation of FDI are decisive for achieving these aims (Fig 3).

The standardisation of FDI tools a nd components w ill significantly reduce the complexity and thus costs for device and system manufacturers: Parallel development and maintenance expense in the fieldbus organisations is avoided.

Host ma nufacturers have lower expense because they only have to procure, integrate and maintain one standardised interpreter component.

T he e x p e n se for de v ice manufacturers is lower because a significant part of the EDD is proto col - indep e nde nt a nd can therefore be used multiple times. Host-specific variants are not required. Standardised development and test tools reduce training expense and increase efficiency in development.

58 industrial automation asia | Oct/Nov 2009

Standard EDDL IEC 61804 FF HART

PROFIBUS

FDT IEC 62453 FF HART PROFIBUS Plus 9 more protocols

Device vendor

Device “driver”

Test

Tested package

Control system HART

HCF Design tool

HART EDD format

HCF Test tool

HART EDD format

FF Design tool

FF EDD format

FF Test tool

FF EDD format

Interpreter

PNO Design tool

PNO FF EDD format

PNO Test tool

PNO EDD format

Interpreter

Microsoft Design tool

FF DTM EDD format

FDT DTM tester

DTM

Interpreter FF

PNO

FDT frame application

Fig 2: Device integration today

Standard

Device vendor

Device “driver”

Test

Tested package

Control system

FDI EDDL IEC 61804* FF HART FDI Client

FDI Design tool

FDI EDD format

UIP

PROFIBUS

FDI Test tool

UI engine FDI EDD format

UIP

OPCUA FDI Interpreter FDI Server

UI plug-in FF HART PROFIBUS

*with FDI specific enhancements

The ma nufacturers ca n concentrate on improving their applications instead of having to deal with different versions of the same technology.

The development times for host and device manufacturers are reduced. New products reach the market more quickly.

Interoperability is improved because protocol-specific or hostspecific variants are no longer required. The behavior of an EDD in a standardised interpreter component is always the same.

For these aims to be achieved, it

Fig 3: Standardised device integration

is necessary for a standardised binary format to be defined for the use of EDDL within the FDI technology on a protocol-independent basis. Based on the tools that exist today, it is necessary to provide standardised development and test tools that can be used for the development of FDI device packages for all communication protocols. A standardised EDD interop erabilit y comp one nt should be downwardly compatible with the EDDL formats that currently exist.

ENQUIRY NO. 7702

Market Report

World Demand For Water Desalination To Reach US$13 Billion In 2013 Technological advancements have encouraged the proliferation of desalination techniques.

By The Freedonia Group World demand for desalination products and services is projected to increase 9.1 percent annually to US$13 billion in 2013. Areas with scarce or compromised water supplies will increasingly turn to thermal or membrane desalination techniques to supply water to households, industrial users and, to a lesser extent, commercial consumers such as tourist destinations and agricultural interests.

Much of the expansion of desalination resulting from technological advances will be in the form of membranebased technologies such as reverse osmosis (RO), although similar improvements will allow multiple-effect distillation (MED) to increase its share of the thermal desalination segment.

Last Resort No Longer Traditionally, desalination has been considered a last resort, mainly as a result of costs.

When desalination first became a commercially significant technology in the 1960s and 1970s, it was restricted to areas with no viable alternatives: areas with essentially no fresh water supply, as is the case in some parts of the Middle East, North Africa and the Caribbean; or where local water supplies were so compromised that they could not be rendered useful by conventional water

WORLD WATER DESALINATION DEMAND (million dollars) % Annual Growth 2003- 20082013 2008 2013

Item

2003

2008

World Water Desalination Demand

3946

8425

13000

16.4

9.1

2660 750 740 1170 440 279 567

5895 1595 1590 2710 750 735 1045

9025 2310 2360 4355 1090 1345 1540

17.3 16.3 16.5 18.3 11.3 21.4 13.0

8.9 7.7 8.2 10.0 7.8 12.8 8.1

Africa/Mideast United Arab Emirates Saudi Arabia Other United States Asia Pacific Other Regions

treatment techniques such as sedimentation and filtration.

But technological advances have brought improved equipment, energy savings and, as a result, cost reductions that have allowed desalination techniques to become more accessible.

Worldwide Growth A lthough the desalination industry has outgrown the limited ‘no choice’ areas, the Middle East and North Africa will continue to dominate the desalination market, accounting for well over ha lf of t he world’s desalination capacity, and demand for desalination products and services.

There will be significant gains in the region’s largest markets – Saudi Arabia and the United Arab Emirates – but growth will be faster yet in countries which have

only recently added significant desalination capacity, such as Algeria, Israel and Libya.

Gains are also expected to be healthy in some of the areas where desalination is seen as one among a number of water solutions (along with conservation and recycling).

The A sia/Pacific region is expected to be the fastest growing region through 2013.

Australia is in the process of adding substantial seawater RO de sa linat ion capacit y a long its coa sts, a nd the Chinese government has made desalination a high-priority facet of its broader efforts to address decades of neglecting and abusing its water resources in the interest of economic modernisation.

ENQUIRY NO. 7703

Oct/Nov 2009 | industrial automation asia 59

products & Services ABB:

Adlink:

ABB’s small multipurpose industrial robot, the six-axis IRB 120, is available with a compact version of the popular IRC5 controller.

The robot weighs 25kg and can handle a payload of 3kg (4kg with vertical wrist) with a reach of 580mm.

The model also has a stroke of 411mm and the ability to reach 112mm below its own base.

The IRB 120 can be mounted at any angle, either in a cell, on top of a machine or close to other robots on the manufacturing line. The compact turning radius on axis 1 ensures the robot can be mounted in close proximity to its application.

Adlink’s Matrix MXE-1000 and MXC-2000 series of rugged and fanless I/O platforms are based on the Intel Atom N270. The MXE-1000 provides embedded I/O functions and the MXC-2000 series offers configurable PCI and/or PCI Express slots.

These platforms are the result of combining ADLINK’s expertise in x86 platform design, versatile I/O function development, and thermal design to push fanless systems to a higher standard, including 5G vibration and cable-free durable structure. They include a specifically-designed single board computer to fit the respective fanless chassis that all heat-producing components come in direct contact with the aluminum shell.

Multipurpose Industrial Robot

Rugged I/O Platforms

Enquiry no. 7801

Enquiry no. 7802

Aerotech:

Basler:

The ANT130-L employs a centre-driven, non-cogging, noncontact linear motor and encoder as the driving element. Since the linear motor is a direct-drive device there is no backlash, windup, or ‘stiction’ normally associated with a lead- or ball-screw drive.

The linear motor drive also offers the advantage of higher speeds and accelerations. The compact yet powerful linear motor drives the ANT130-L to a peak unloaded acceleration of 1 g and a maximum velocity of 350 mm/s.

The direct-drive linear motor allows the ANT130-L to make precise, small resolution steps, which is particularly important in alignment applications where step accuracy is critical.

Basler Vision Technologies is adding new features to all scout and pilot area scan cameras produced from September 2009 on. The more than 50 different scout models and 10 different pilot models will be fully equipped with the new firmware during production.

The additional features include: very short exposure times, a trigger delay feature, a combined auto-gain and exposure feature, and a mirroring function at full grabbing speed. Multicast support that makes camera image data available on more than one PC will also be added via the free pylon driver package.

Linear Motor Drive

Enquiry no. 7803 60 industrial automation asia | Oct/Nov 2009

New Firmware For Cameras

Enquiry no. 7804

products & Services

Baumer:

Beckhoff:

In quite a number of fill level applications there are liquids to be detected which require sensor housings and media containers to be made of materials of strongly improved properties due to their chemical reactivity. Baumer capacitive sensors provide innew approaches to many of these challenging cases.

Since the sensors’ electrical field of detection is capable of penetrating through insulating materials such as plastics, glass, cardboard etc, non invasive detection of both liquids and solid matter is possible from the outside. Capacitive sensors can therefore monitor fill levels in closed containers whilst being attached to the outside container wall.

The C6930 control cabinet PC from Beckhoff combines a 3½-inch motherboard designed for Intel Core Duo or Core 2 Duo, a wide range of PC interfaces, up to three Ethernet ports.

The C6930 offers high data security through an integrated RAID system for mirroring hard disks. Cooling fins behind the right-hand side panel enable fanless operation of the PC at temperatures up to 55 °C (131 °F).

The C6930 has an on-board SATA RAID controller for mirroring two hard disks. It can be used for convenient configuration of RAID applications supported by TwinCAT automation software.

Capacitive Sensors

Ultra Compact Industrial PC

Enquiry no. 7805

Enquiry no. 7806

Flow Technology:

GarrettCom:

Flow Technology’s DC-F/IM (Ingredient Measurement) positive displacement (PD) flow meter system. Featuring a bearingless design with only two moving parts, the DC-F/IM is ideal for measuring high-viscosity fluids in food applications where batch repeatability is desired.

The DC-F/IM is suitable for measuring flow rates as low as 0.001 Gallons per Minute ( GPM ) and is designed for applications involving high pressure and pulsating flow streams. Due to its unique geometry, the PD meter can be utilised in the optimal line size, which minimises pressure drop and enables accurate measurement across the entire desired flow range.

GarrettCom’s Magnum 6KL managed edge switch is a compact, environmentally sealed 10-port Ethernet switch with an ambient temperature range of -40ºC to 85 ºC. The base unit includes four 10/100Mb copper ports (regular or PoE), plus up to six additional ports which can be combinations of Gigabit, 100Mb, and 10Mb fibre ports and copper ports.

The 6KL switch is packaged in a hardened, convectioncooled sealed metal box, with optional conformal coating, and offers high EMI noise immunity.

PD Flow Meter System

Enquiry no. 7807

Ethernet Switch

Enquiry no. 7808 Oct/Nov 2009 | industrial automation asia 61

products & Services

Harting:

Ixxat:

PushPull is a family of rugged connectors for transmitting optical and electrical communication, as well as signals and power with IP65/IP67 protection class.

Han PushPull Power is a compact five-pole power connector up to 690 V and 16 A. A complete connector family in metal and plastic design is available for signal and power transmission.

Assembly is carried out by crimp technology or the Han-Quick Lock rapid termination technology.

Panel feed throughs bring the power into the switch cabinet or directly into the device. Straight or angled male inserts conduct the power to the PCB for device integration.

Ixxat’s FPGA based Industrial Ethernet Module (IEM) now integrates a high-capacity Switch-IP which enables customers to implement powerful and economic line topologies.

The IEM is based on a powerful Altera Cyclone III FPGA which includes, besides an integrated 32-bit CPU, PHYs, magnetic modules and RJ45 jacks, the new 3-port switch IP for Profinet, EtherNet/IP and Modbus-TCP. The IP implements a store-and-forward switch and is explicitly designed for real-time Ethernet networks. An implementation as cut-through switch is already in preparation.

Rugged Connectors

Industrial Ethernet Module

Enquiry no. 7809

Enquiry no. 7810

OmniVision:

Omron:

OmniVision Technologies’ 1080p high definition (HD) CMOS image sensor OV2715 is built on a 3-micron OmniPixel3-HS pixel, delivering low-light performance of 3300 mV/(lux-sec) and a peak dynamic range of 69 dB. It is a no-compromise 1080p HD sensor that offers the HD video format with a display resolution of 1920 x 1080 pixels and operates at 30 frames per second. Offering a zero degree chief ray angle, the OV2715 is capable of operating within a temperature range of -30°C to +70°C. The company’s OmniPixel3-HS pixel technology has already been proven in high quality surveillance applications and is also available in the 720p format in the OV9715.

Omron’s CP1E series micro programmable controller provides approximately 20 to 160 I/O points. All CPUs can be connected to a computer via commercially available USB cable and support software with ‘smart input’ intuitive operation for faster programming.

Two types of CPU Units are available: E-type Basic CPU Unit is economical with basic functionality whereas the N-type Application CPU Unit supports Programmable Terminal connection, position control and inverter connection. The CP1E Series shares the same architecture as other Omron’s CP1 series but with a smaller yet powerful instruction set. This allows easy upward migration across all platforms.

High Definition Sensor

Enquiry no. 7811 62 industrial automation asia | Oct/Nov 2009

Micro Programmable Controller

Enquiry no. 7812

products & Services products & Services

PI:

Turck:

Physik Instrumente (PI) is switching to a generation of 24-bit resolution interfaces for its nanopositioning stage controllers.

The new interfaces will allow better than 100 picometers command resolution even on the latest generation long travel piezo nanopositioning stages (1 mm and up) such as the PIHera series closed-loop flexure stages.

The controllers come in a variety of bench-top, rack-mount and OEM card versions from single-channel units for simple linear actuator applications to multi-axis system controllers with 12 channels per rack.

The piezo controllers come with Windows installation software, DLLs and LabVIEW drivers.

Turck has expanded its line of BIM-UNT cylinder position sensors with a 2-wire DC version, along with a NAMUR option for intrinsically safe applications. The cylinder position sensor’s wear-free design and short circuit protection make them a viable alternative to electromagnetic switches in the automotive industry. To further their applicability in this industry, Turck has integrated a weld resistant TPU cable.

With a total length of only 28 mm, the BIM-UNT is one of the most compact cylinder position sensors on the market.

The active sensing faces are located directly at the end of the sensor to safely detect the piston rod’s end position on compact, short-stroke cylinders.

24 Bit Nanopositioning Stage Controllers

Cylinder Position Sensors

Enquiry no. 7813

Enquiry no. 7814

Wago:

Witte:

A developed coupler for the Wago I/O system opens up the entire spectrum of Sercos III services for users. With this third generation, Sercos, originally a pure drive bus, has become a full-fledged system bus with a uniform I/O profile and the ‘CIP safety on Sercos’ safety protocol. All of the real-time characteristics have also been retained.

The Wago coupler is integrated into the overall system via the Sercos III-I/O profile using SDDML device description files.

All features, such as the redundant ring topologie, synchronous slave-to-slave communication (CC), hot plugging, as well as the independent Ethernet IP channel are supported by this coupler.

To accelerate the entire process of workpiece exchange and reduce standing times of measuring machines to a minimum, Witte has developed an automatic loading system.

It can be equipped with three, four, five or more pallets and/or preparation/parking areas as application demands. Depending upon requirements and space conditions the system can be circular, shelf, paternoster, shuttle or bridge type.

Transfer from preparation/park position to measuring machine is possible via turntables, transfer tables and leveling systems. Depending upon type of measuring machine passthrough systems for in line measuring operations can be integrated.

System Bus

Automatic Loading System

Enquiry no. 7815

Enquiry no. 7816 Oct/Nov 2009 | industrial automation asia 63

EVENT PREVIEW

CIA

2009

CIA2009, the process engineering, controls instrumentation and scientific equipment exhibition, gathers the latest technologies and solutions that caters to industry demands to enhance product quality and expand production capacity while improving process safety and plant availability. The event boasts a 30 year track record and will return to Suntec Singapore from December 1–4, 2009.

The event consists of ControlsAsia2009, InstrumentAsia2009 and AnaLabAsia2009. Ongoing infrastructure developments within the energy, downstream petroleum and chemical sectors in Asia continue to be the key drivers of process technology demand on show at ControlsAsia2009 & InstrumentAsia2009.

A na LabA sia 20 09 brings key analytical instrumentation solutions from across the globe to the growing petrochemical, biodiesel, pharmaceutical and biotechnology industries in this part of the world. Robust growth in China and other Asia Pacific areas over the last few years have contributed significantly to the US$36 billion (S$50.8 billion) global market for analy tical instrumentation.

64 industrial automation asia | Oct/Nov 2009

Strong Exhibitor Participation Global market and technology leaders will seek to gain a larger foothold in Asia by participating in CIA2009.

T he S i n ga p o re p av i l io n , spearheaded by The Singapore Manufacturers’ Federation (SMa) and supported by IE Singapore, returns with a strong presence of 35 companies this year.

Other national and regional group pavilions returning after a good showing in 2007 include China, France, the German State of Baden Wurttemberg, South Korea and the Gambica group from UK, which is expected to be represented by even more companies this year.

Special Events CIA2009 will also see prominent pre sence a nd suppor t from well-regarded regional industry a ssociations like CH W M EG , Japan Analytical Instruments Manufactures Association (JAIMA) and Korea Scientific Instruments Industry Cooperative (KSIIC).

The JAIMA Forum, organised

by JAIMA and held in conjunction w ith A na L abA sia 20 09 w ill investigate critica l issue of

c he m ic a l cont a m i nat ion o f products in some Asian countries.

The seminar on Responsible Waste Stewardship organised by CHWMEG will address the apparent lack of regulatory requirements for soil and groundwater standards in many Asian countries and how industry can benefit from regulatory schemes implemented by the USA’s CERCLA (Superfund) law.

Delegates will also be introduced to the newest hazardous waste technology being deployed in the region.

Held alongside CIA2009 at the same venue is EnviroAsia2009, the four th env ironmenta l technologies exhibition and conference. EnviroAsia addresses the international concerns of sustainable development through w a te r, e n v i r o n m e n t a l a n d sustainable energy management solutions.

December 1 – 4, 2009 Suntec Singapore ENQUIRY NO. 7901

Industrial Busand Wireless Technology The

Conference

INDUSTRIAL plant efficiency continues to be a fundamental concern for process plants in key sectors such as chemical processing, petrochemical and oil and gas refining and production.

Margins for corporations are challenged by recessive economic pressures a nd the socia l responsibility to reduce their carbon footprint, prompting them to look towards deploying more environmentally-friendly practices.

The Industrial Bus and Wireless Technology Conference, to be held for the first time from December 3 – 4, 2009 at Suntec Singapore, aims to address these challenges, to enable greater robustness, safety and dependability of plant operations.

industrial bus technology, an alldigital industrial network system for real-time distributed control, connecting microprocessorsbased control and field devices bi-directionally.

Bus deployment benefits can be seen throughout the processes of installation, maintenance and commissioning. The technology, together with the deployment

of wireless networking, allows for remote access to status and diagnostic information, enables predictive maintenance strategies via continuous condition monitoring and sees major cost savings in reduced point-to-point wiring and associated equipment.

Implementing Wireless Technology The conference is designed by industry leaders for industry professionals from multiple levels within plant design and operations.

The conference will address critical underlying challenges on interoperability a nd the increasing reliability of wireless a rc h ite c t u re . I ndu st r y a nd technology experts will give detailed perspectives into case studies of various bus and wireless technology implementations.

T he t wo - day co n fe re nce comprises two tracks which will run in parallel - Plant Operations & Ma intena nce a nd Control Systems & Design. The technical panel, responsible for shaping the conference programme and ensuring that the topics are the most relevant and comprehensive, comprises top executives from the major industry bodies, technology providers and technology users.

December 3 – 4, 2009 Suntec ENQUIRY NO. 7902 Singapore

Bus Deployment Benefits These operational gains stem from the efficient design of plants for long-term operability based on Oct/Nov 2009 | industrial automation asia  65

EVENT PREVIEW

Manufacturing

Indonesia 2009

COUPLING signs of an upturn in the world economy with Indonesia’s robust domestic market, demand for space at Indonesia’s largest Machinery Trade Exhibition, Manufacturing Indonesia 2009 is high.

The Manufacturing Indonesia serie s of trade ex hibitions, incorporating Machine Tool Indonesia, Industrial Automation Indonesia and Vehicle Manufacturing Indonesia will be held for the 20th time, December 2 – 5, 2009, at the Jakarta Exhibition Centre, Jakarta.

A s w it h prev iou s ye a rs, Machine Tool Indonesia will be the JIMTOF 2010, the 25th Japan International Machine Tool Fair, will be held at Tokyo Big Sight in Tokyo, Japan for a six-day period from October 28 – November 2, 2010.

The previous show in 2008 showcased integrated machine tools, software and peripherals.

With some 80,000 sq m of exhibition space, it housed a total of 851 exhibitors using 5,233 booths and 142,408 registered visitors.

Says Toshiomi Shono, president of Japan Machine Tool Builders Association: “We predict that a lt hough cu r rent e conomic situation is very tough but come next autumn when JIMTOF 2010 is being held, many machine tool makers will get back on a recovery track. We are very confident that for the exhibition, we will receive applications from Europea n machine tool makers as well as the makers from East Asia including China.” Mr Shono continues: “We are also expecting about 142,400 visitors as a whole and about 66

industrial automation asia | Oct/Nov 2009

biggest component of the show, encompassing over 9,000 sq m of exhibition space in hall A. National groups from China, Germany, South Korea, Singapore and Taiwan will be present.

International Affair This year for the first time, over one hundred companies from India under the auspices of the Engineering Export Promotion Council of India will be participating. The Indian government will be organising INDEE, the Indian Engineering Exhibition alongside Manufacturing Indonesia. In addition, Plastics and

Rubber and ProPak Indonesia will once again be held in conjunction with Manufacturing Indonesia.

I n a dd it io n , t he Ta i w a n Machinery Builders Association will be bringing a number of their members alongside TAMI, the Taiwan Association of Machinery Industry. Over 200 companies from Taiwan are expected to showcase the latest machinery equipment.

Hall D will feature products fo r I n du s t r i a l A u to m a t io n , Vehicle Manufacturing as well as mainstream manufacturing. A high level conference and a large number of individual exhibitor seminars will be held in conjunction with the exhibition.

December 2 – 5, 2009 Jakarta Exhibition Centre Jakarta, Indonesia ENQUIRY NO. 7903

JIMTOF 2010

10,000 overseas visitor without multi-entries count.”

Indoor exhibition space is expected to be 82,660 sq m at the event next year. Exhibits include machine tools (metal cutting, metal forming), machine tool accessories, high speed steel tools, cemented carbide tools, precision measuring machines and controller and related software.

O rga n i se d by t he Jap a n

Machine Tool Builders Association and Tokyo Big Sight, the purpose of the event is to contribute to the development of the industry and promote trade through increased international transactions and technical exchanges of machine tools and their related equipment.

October 28 – November 2, 2010 Tokyo Big Sight Tokyo, Japan ENQUIRY NO. 7904

CalendarOOff Events2009 OCTOBER 5 – 8 SCM Logistics World 2009 Raffles City Convention Centre Singapore Terrapinn Email: enquiry.sg@terrapinn.com Web: www.terrapinn.com

7 – 10 Manufacturing Technology World SMX Convention Center Pasay City, Philippines Global-Link MP Email: info@globallinkph.com Web: www.globallinkph.com

7 – 11 Bangkok RHVAC 2009 Impact Arena Exhibition & Convention Centre Muang Thong Thani Thailand Royal Thai Government Office of Trade Fair Activities Email: rhvac@depthai.go.th Web: www.bangkok-rhvac.com

8 – 11 Taiwan RFID TWTC Nangang Exhibition Hall Taipei, Taiwan Taiwan External Trade Development Council (TAITRA) Email: rfid@taitra.org.tw Web: www.rfidtaiwan.com.tw

13 – 15 Wire Southeast Asia BITEC Bangkok, Thailand Messe Düsseldorf Asia Email: wire@mda.com.sg Web: www.wire-southeastasia.com

14 – 16 JEC Show Asia 2009 Suntec Singapore JEC Composites Email: visitors@jeccomposites.com Web: www.jeccomposites.com

14 – 17 Oil & Gas Indonesia 2009 Jakarta International Expo Kemyoran Jakarta, Indonesia PT Pamerindo Buana Abadi Email: info@pamerindo.com Web: www.pamerindo.com

15 – 17 EPM Linkage Vietnam 2009 Saigon Exhibition & Convention Center Ho Chi Minh City, Vietnam Chan Chao International Email: machine@chanchao.com.tw Web: www.epmlinkage.com

22 – 25 Metal Technology Show 2009

18 – 20 NDE Tokyo 2009

26 – 27 Carbon Forum Asia

19 – 22 Metalex 2009

Putra World Trade Centre Kuala Lumpur, Malaysia Fairs & Events Management Email: enquiries@femsb.com Web: www.femsb.com/MTS2009 Raffles City Convention Centre Singapore International Emissions Trading Association (IETA) and Koelnmesse Email: s.sim@koelnmesse.com.sg Web: www.carbonforumasia.com

26 – 29 CeMAT Asia

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

27 – 31 Korea Metal Week 2009

Korea International Exhibition Center Seoul, South Korea Korea Trade Fairs Email: master1@ktfairs.com Web: korea-metal.com/english

28 – 31 Advantech World Partner Conference

Suzhou International Expo Center Suzhou, China Advantech Email: sg@advantech.com Web: www.advantech.com

Tokyo Big Sight Tokyo, Japan Japan Management Association (JMA) Email: nde2009@convention.jma.or.jp Web: www.jma.or.jp/nde/en BITEC Bangkok, Thailand Reed Tradex Email: metalex@reedtradex.co.th Web: www.metalex.co.th

DECEMBER 1 – 4 CIA 2009

Suntec Singapore Singapore Exhibition Services Email: car@sesallworld.com Web: www.cia-asia.com

2 – 4 Semicon Japan 2009

Makuhari Messe Chiba, Japan Semi Email: jshowsinfo@semi.org Web: www.semiconjapan.org

3 – 4 Industrial Bus and Wireless Technology Conference

Suntec Singapore Singapore Exhibition Services Email: joa@sesallworld.com Web: www.cia-asia.com/conf_prog.htm

NOVEMBER 11 – 12 Rockwell Automation Fair Anaheim Convention Center California, USA Rockwell Automation Email: klester@ra.rockwell.com Web: www.automationfair.com

16 – 20 Singapore International Energy Week

Singapore Singapore’s Energy Market Authority (EMA) & Energy Studies Institute (ESI) Email: ema_siew@ema.gov.sg Web: singapore.iew.com.sg

18 – 20 Clean Energy Expo Asia

Shangri-La Hotel Singapore Koelnmesse Email: c.hor@koelnmesse.com.sg Web: www.cleanenergyexpoasia.com

NOTES To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Assistant Editor IAA. Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building #04-02, Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2805 Email: derekrodriguez@epl.com.sg

Oct/Nov 2009 | industrial automation asia

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Advertising Index

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ABB INDUSTRY PTE LTD

7

066

EXXON MOBIL ASIA PACIFIC

1

036

FLUKE

25

073

FUJI ELECTRIC FA SINGAPORE PTE LTD

3

070

GUANGZHOU GUANGYA MESSE FRANKFURT

33

069

LINKVUE SYSTEM PTE LTD

11

074

MITSUBISHI ASEAN CC-LINK PROMOTION CENTRE

IBC

007

MITSUBISHI ELECTRIC ASIA PTE LTD

OBC

059

MOXA INC

29

064

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

MP ASIA PTE LTD

15

075

KOREA:

NATIONAL INSTRUMENTS

9

067

N-TRON

13

072

ROCKWELL AUTOMATION SEA PTE LTD

IFC

041

SINGAPORE EXHIBITION SERVICES PTE LTD (BUS & WIRELESS)

41

068

SINGAPORE EXHIBITION SERVICES PTE LTD (CIA)

53

052

VIPA

19

071

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ENQUIRY NO. 007

From control to optimization of your system in each network level. A new integrated industrial Ethernet network concept with Gigabit.

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