www.pacetoday.com.au
PACE PROCESS & CONTROL ENGINEERING
No longer a pipe dream Solar generated power could provide significant amounts of clean energy. Special Report 15
World-class training ISA courses provide practical skills in a vendorneutral format. IICA News 30
Pushing mining automation ZZZ DQ\EXV FRP DX AUGUST 2011
VOL.64 NO.7
INSIDE THIS ISSUE
Management 6
Adoption rates go up The total market for fieldbus products is rapidly approaching a billion dollars. Energy Management 9
Boost profitability Companies must embrace an integrated approach. Technology Report 12
Simulation modelling The greatest investment when modelling the behaviour of a machine occurs very early. Application Feature 18
Wireless and SCADA Integrate video surveillance into existing networks without hindering communications. Case Study 24
Precise AC drive control AC drives eliminate energy waste caused by oversized HVAC systems.
BY KEVIN GOMEZ IF MINING is big business in Australia, mining automation is no small change. Last month, Rockwell Automation organised the Executive China-Australia Mining Forum to showcase key technologies and share information. The Forum in Brisbane attracted over a hundred engineers from the two countries. “The objective is to increase collaboration between mining automation groups in Australia and in China – at the end user level, as well as for Chinese investors who are investing in new Australian mines,” explains Geoffrey Irvine, Industry Solutions Manager, Rockwell Automation. There is also robust trade at the equipment supply or OEM level. “It’s not just Australian OEMs that are supplying into China,” notes Irvine. “Chinese OEMs, who are new to the local mining market, are emerging particularly strong and supplying equipment here.” The forum was split into two streams: Process & Automation and Power & Safety. Topics ranged from ‘Best Practices for HMI Graphic Design’ and ‘Production and Delay Reporting Systems for Mining Operations’ to ‘Sustainable Longwall Coal Shearing Systems.’ Rockwell Automation cut back on the marketing spiel and organised the Forum as a customer application driven event. “The direct involvement that Rockwell Automation has in terms of these talks is a fairly thin layer,” explains Irvine. “This works better than a comprehensive product presentation. Making the connection between the application and how our equipment is utilised, is a very strong selling point.”
GEOFFREY IRVINE: The remote operating mining centre is a popular concept. Irvine played a key role in pulling the event together and spent some time talking to end users to determine the hot topics in the mining industry today. He highlights the session on remote operating centres. “Everybody wants to do that. It’s similar to what many large mining companies have developed and implemented,” he says. The Forum was ‘opened’ by Minister for Foreign Affairs, Kevin Rudd, who was beamed in via a pre-recorded video message. He pointed to a recent study by the Department of Foreign Affairs and Trade which revealed that the average mining company spends $24.40 on embodied services for every $100 of coal extracted in Australia. “It’s not just the commodity but also
Post Print Approved PP255003/00539
Put Integrated Architecture — at the heart of your machine CompactLogix offers a scaleable, integrated control and motion solution to meet your needs simply and effectively, while reducing costs. www.rockwellautomation.com.au
the sale of services built into that commodity and this fuels a whole lot of other jobs in the economy,” said Rudd. Rudd also used the opportunity to push the Australia-China 2.0 plan which is designed to help Australia’s businesses expand their links with five of that country’s booming regional second-tier cities. “Today’s event, and the issues you will be discussing, are important to maintain the momentum of our trade,” he remarked. “Our skilled professionals, advanced extraction processes and cutting edge technology have all made Australia a leader in the global minerals industry. We’re also a leader in mining equipment, technology and services.” www.rockwellautomation.com.au
| BS11-02E |
Four components, one system: New Automation Technology. Motion Servo Drives Servomotors
IPC Industrial PCs Embedded PCs Motherboards
I/O EtherCAT components IP 20 Bus Terminals IP 67 Fieldbus Box
www.beckhoff.com.au Setting standards worldwide: PC- and EtherCAT-based control solutions from Beckhoff. As renowned specialists for open automation systems, Beckhoff offers components for IPC, I/O, motion and automation applications that can operate individually or integrated as a precisely adapted control system. New Automation Technology from Beckhoff represents versatile automation solutions that are used in a wide range of applications worldwide. The growing presence of Beckhoff in more than 70 countries ensures consistent support around the globe. IPC I/O Motion Automation
Automation Software PLC Software NC/CNC Safety
NEWS
EDITOR’S MESSAGE
PACE
Carbon Tax dilemma
PROCESS & CONTROL ENGINEERING
Published monthly by Reed Business Information Pty Ltd Tower 2, 475 Victoria Avenue Chatswood NSW 2067 Locked Bag 2999 Chatswood DC NSW 2067 Tel: (02) 9422 2999 Fax: (02) 9422 2977 ABN 80 132 719 861
Publisher: Michelle Graves Email: michelle.graves@reedbusiness.com.au Editor: Kevin Gomez Tel: (02) 9422 2976 Fax: (02) 9422 2722 Email: kevin.gomez@reedbusiness.com.au
Kevin Gomez Editor
Senior Journalistt: Isaac Leung Tel: (02) 9422 2956 Email: isaac.leung@reedbusiness.com.au Account Manager: Tim Richards Tel: (02) 9422 2818 Mobile: 0407 948 774 Email: tim.richards@reedbusiness.com.au QLD Sales Manager: Sharon R. Amos PO Box 3136, Bracken Ridge, QLD 4017 Tel: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 Email: sharon.amos@reedbusiness.com.au New Business: Alex Evans Tel: (02) 9422 2890 Email: alex.evans@reedbusiness.com.au Graphic Designer: Justine Dunn Email: justine.dunn@reedbusiness.com.au Production Coo-ordinator: Jennifer Collinson Tel: (02) 9422 2657 Fax: (02) 9422 2722 Email: jennifer.collinson@reedbusiness.com.au
Next Issue Fluid Handling Information Integration ● Environment & Sustainability ● ●
IT COULD be a feast or a famine. I must admit, the carbon tax poses some intriguing scenarios for our industry. Politics aside, if the Labor Government’s current carbon tax does indeed take a hold, industry in Australia will be forced to spend time, money and resource to monitor their operations processes, analyse their energy consumption, manage the energy efficiency of their production facilities as well as their offices and report on their overall CO2 emission outcomes. This will require the process control and automation industry to supply equipment, services and solutions on a scale we have not seen before. On the flip side, we may well lose the whole lot, if the more vocal elements in manufacturing industry (and the Coalition) are to be believed. They claim minimal manufacturing and processing is likely to remain in Australia, post carbon tax. If that comes to pass, who will consume energy that will require monitoring and managing? Whatever the outcome, energy efficiency has now taken centre stage and companies with products and services in this space have a
unique opportunity to educate and market to a more receptive audience. The PACE office is deluged with white papers, application notes and new service/product offerings from suppliers in this space as they jockey for position and battle for top-of-mind recall when it comes to energy efficiency. This edition alone carries three energy-related feature stories. An interesting development comes from CSIRO who see wealth in Australia’s titanium ore. Like all our minerals, we dig, export and buy back exorbitantly-priced finished goods. If we convert just one per cent of the nation's titanium ore reserves each year to metal for high-value manufactured items, CSIRO estimates we would achieve significant export earnings for another 9,000 years. A University of Adelaide student has taken up the challenge and designed a titanium-based Prandtl-attack tube. This unique design combines a pitot-static tube and the measurement of angle of attack into a single instrument. Hats off to you, Michael Bowen. Australia needs a few thousand like you. Kevin.Gomez@reedbusiness.com.au
VIEWPOINT Printed by: GEON 20 Baker Street, Banksmeadow NSW 2019 Tel: (02) 8333 6555 SUBSCRIPTION: $99 pa incl GST OVERSEAS SUBSCRIPTIONS: NZ: $A109 pa & OS: $A119 pa CUSTOMER SERVICE: 1300 360 126
Copyright © Reed Business Information 2011 All rights reserved. No part of this publication may be reproduced or copied in any form or by any means without the written permission of the publisher.
Average Net Distribution Period ending March '11 7,100
64 Tags 128 Tags 256 Tags 500 Tags
FROM
FROM
FROM
FROM
Operator Paradox: The system must adapt to user needs BY JIM PINTO OPERATOR interface, annunciators and alarm systems in large automation and processing plants have simply evolved from legacy systems, “enhanced” with a plethora of new features and functions available just by clicking software settings. But effective management is overlooked. Most process plants keep trying to train operators to cope with the challenges of continually increasing safety and efficiency requirements. In the developed countries, the shortage of experienced operators is compounded by the retirement of an aging workforce. In
Second and Third World countries, which is where growth is occurring today, skilled operators are simply not available. So, when the term “operator interface” is used, who is the operator? And where does one find enough good operators to operate the system? And how long does it take to train them? Traditionally, operators build knowledge and experience through handling normal production as well as abnormal emergencies and events. They learn how to cope with abnormal situations and emergencies through similar past experiences. What is needed is for the system to
“learn” continuously from operator experiences, normal and abnormal, and that learning should remain in the system, minimising dependence on experienced human operators. The operator paradox is this: Improved effectiveness comes not just from training operators to use increasingly more complex systems, but also from developing systems that adapt effectively to maximise throughput with minimal operator involvement. If operators cannot be trained to use the system, the system must adapt to the needs of available operators. Jim@JimPinto.com
$908
$2,057
Place your order online! visit www.intouchspecials.com.au
$2,420
for pricing, product options and detailed product specifications.
$1,089
AUGUST 2011 www.pacetoday.com.au 3
NEWS
TOP TWEETS
RESEARCH
Here’s what you may have missed this July if you weren’t following @pacetoday on Twitter:
Get more from titanium ore says CSIRO
❏ Energy and resources institute opened in Newcastle. http://dlvr.it/bDdQC
AUSTRALIA has the world’s largest reserves of titanium ore. There are numerous potential uses, from hip replacements, to cookware, to stealth fighter planes. Today, most our titanium ore is shipped overseas, and bought back after processing. Australia could keep that up for 90 years, at the current production rate. But John Barnes has a better idea. If we converted just one per cent of the nation's ore reserves each year to metal for high-value manufactured items, Barnes estimates they would achieve the same annual export earnings – for another 9,000 years. As the newly appointed leader of the CSIRO’s Titanium technologies theme, Barnes aims to turn the country's natural wealth into high-wage jobs for Australians, and high-value products for the world. Titanium’s phenomenal performance characteristics are critical to the aero-
❏ Cardno acquires Perth based design and instrumentation company. http://dlvr.it/ZM33d ❏ Additive manufacturing can get us more from ore says CSIRO titanium expert. http://dlvr.it/ZLlWv ❏ Federal Government seeks water projects to fund. http://dlvr.it/Zpmjy Follow @pacetoday on Twitter for the latest news, analysis, new product information and commentary. And never miss out again.
space industry. In his previous job, Barnes was a Senior Manager with Lockheed Martin Aeronautics Skunk Works, working on the development of advanced fighter jets and stealth aircraft. He has also worked with Honeywell suppling marine gas turbine engines for fast patrol boats and mega yachts. Barnes believes the true potential of titanium remains to be uncovered. The arrival of additive manufacturing technologies, which generate 3D shapes directly, changes the game. Instead of machining a product out of a block of metal, where up to 90 per cent of the metal is lost as waste, additive manufacturing builds up products layer by layer out of powder or metal wire, using energy from lasers or electron beams to bind the metal into a shape. It is faster, cheaper, and cleaner – and it will change the way the world does business.
Australia is well-placed to get ahead in the race, Barnes says. We already have the highly skilled, educated workforce needed for computer-aided design of products and management of the high-technology additive manufacturing facilities. With the right technology, we would gain a powerful edge over mass-scale, low-wage producers overseas. Additive manufacturing enables labour efficient manufacturing, and is suited to investment by small businesses, so there is huge potential for growth. So Barnes is working with his CSIRO team to implement additive manufacturing methods locally to make items Australia can sell overseas. He is also working hard to increase awareness and excitement in Australia’s next generation of designers and engineers about the potential of titanium. www.csiro.au/science/ Titanium-technologies
Performance Measurements Are Within Your Control As industrial systems increase in complexity, optimizing your system with advanced measurements and control is critical. The open NI LabVIEW graphical development environment and NI CompactRIO hardware can help reduce costs with precision measurements, machine vision, motion control, and the ability to connect to existing automation equipment through industrial communication. PRODUCT PLATFORM NI LabVIEW NI CompactRIO NI Vision Products NI Motion Control Products NI Wireless Sensor Network
>>
View seven ways to boost your measurement performance at ni.com/precision
©2011 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 01407
4 www.pacetoday.com.au AUGUST 2011
Australia: 1800 300 800 New Zealand: 0800 553 322
NEWS
INNOVATION
Holden’s de-bottleneck tool wins engineering award A BOTTLENECK Indicator Tool (BIT) software system for optimising manufacturing, developed by GM Holden’s Virtual Manufacturing Engineering Manager Gregory Linke, has won the 2011 Society of Automotive Engineers Australasia Bronze Automotive Engineering Excellence Award. The manufacturing tool builds on the known “Theory of Constraints” concept to identify bottlenecks in complex manufacturing processes. The BIT algorithm and processing methodology is based on real time computer analysis of the work flow through the system's work station buffer areas (where one process is completed and another begins). The BIT requires only easily validated buffer contents data, which makes data acquisition and calibration readily achievable. The benefits of BIT are far reaching, including accuracy, ease of calibration, low deployment cost and negli-
ENGINEERING AWARD WINNER: Gregory Linke (L) collects the Bronze SAE-A Award for his Bottleneck Indicator Tool from Patrick Ross.
gible ongoing maintenance. The BIT package identifies “hidden” bottlenecks missed by other systems and includes a tool box of reports that deliver high levels of detail in a user friendly web browser visual format. During the initial three month deployment at Holden’s Elizabeth, South Australia Vehicle Assembly Plant,
volume increased by 60 units a day. The BIT software has been identified as Best GM Practice and is being considered for global deployment. Innovations to reduce engine emissions and fuel consumption, and talented young engineers were among the other winners of the 2011 Society of Automotive Engineers - Australasia
(SAE-A) Automotive Engineering Excellence Awards presented in Melbourne last month as part of Australian Automotive Week. The other 2011 SAE-A Awards included: ❏ Gold: Frank Will, Deakin University senior lecturer, for creating the environmentally friendly OVER7 – Engine Waste Heat Recovery system. ❏ Silver: SMR Automotive Australia with the University of South Australia, for a lightweight integrated plastic rear vision mirror. ❏ Certificate of Commendation: Vaughan Bolwell, MDesign, for the Bolwell Edge Caravan. ❏ Young Engineer: Stephanie Radion, Sr Engineer, Seating, GM Holden. ❏ Young Engineer Runner-up: Christopher Ebejer, Team Leader Reliability Testing, Automotive & Body Electronics, Robert Bosch Australia. www.saea.com.au
AUGUST 2011 www.pacetoday.com.au 5
OPINION
CONTROL
Adoption rates skyrocket Fieldbus-enabled control in the field increases loop performance, writes Dick Hill.
R
EPLACING analogue 4-20 mA technology with a digital network was a major driver behind the development of Foundation fieldbus technology. However, what really differentiates Foundation fieldbus from Profibus PA, HART, and other process automation technologies, is the incorporation of a function block structure and other supporting functions that make Foundation technology a complete infrastructure for process automation. By allowing control functionality to be embedded in the field devices themselves, Foundation fieldbus enables a degree of availability that approaches that of single-loop controllers. By distributing the control functions out to field-mounted actuators or measurement devices, there is no single point of failure in the system above the H1 level. Thus, even if a failure should occur in the HMI or plant network, the fieldbased control loops can continue to function. A backup Link Active Scheduler (BLAS) can also be used to enable a field control loop to continue functioning even if there is a failure in the primary LAS. What’s more, in cases where control normally resides in the DCS, field-level control can add another level of redundancy. Many end users have already managed to avoid unplanned downtime when field-level control took over after a failure in the DCS.
Reduce data transfers Evidence suggests that control in the field provides an 80 percent increase in meantime between failures compared to traditional DCS control. The increased MTBF, combined with the reduction in data transfers required, substantially increases reliability and availability. The overall reduction in network traffic (even with the increased device condition, status, and other data typically passed from fieldbus devices to the DCS) also increases network availability. In addition to increasing availability and reliability, field-level control also 6 www.pacetoday.com.au AUGUST 2011
increases flexibility. With basic loop control performed in the field devices, dedicated process controllers can be freed up to handle higher-level functions, such as advanced control and optimisation. Foundation fieldbus allows for “dynamically instantiable function blocks.” This means that users can activate function blocks in different components of the system as required. In addition to basic PID control blocks, users also have access to a large library of other block types. These include switches, alarms, and so on. Foundation fieldbus adoption has skyrocketed over the past several years, particularly in the power and HPI industries. ARC estimates that the total market for fieldbus products and services is rapidly approaching a billion dollars. Users that actually implement the control in the field functionality, however, still represent a small minority. In ARC’s view, the reason most users don’t take advantage of control in the field is due to the perception that it compromises reliability and availability, and provides little direct economic impact or business value proposition to the manufacturing enterprise. The reality is far different.
Adoption has skyrocketed over the past several years and ARC estimates that the total market for fieldbus products is rapidly approaching a billion dollars. Until recently, there had been no comprehensive study that proved the business value proposition of control in the field. Most of the evidence was anecdotal. The results of real world control in the field applications, however, show that control in the field can provide a path to single loop integrity and truly distributed control for many flow and pressure loops in a process plant or mill.
Control in the field A few years ago, UK-based, Industrial Systems and Control Ltd. (www.iscltd.com) released a study called, “Control in the Field: Analysis of Performance Benefits.” In a series of illustrative simulation
studies, ISC determined that control in the field has the potential to offer improved control loop performance due to its ability to offer faster sample rates and shorter latencies in the read-executewrite cycle of a control loop. ISC examined the differences in timing and sequencing associated with control in the field versus a scheme employing control in the DCS to establish typical latencies and sample rates that limit control performance. ISC tested many different scenarios and process dynamics and the report outlines the results and corresponding benefits. While all control in the field loops can benefit from increased integrity, flexibility, and reliability, ISC found that control loop performance benefits can be quite significant in fast process loops, such as those found in combustion control or compressor control applications in power generation and other plants. ARC believes that control loops with complex interactions can also benefit from improved loop performance. [Dick Hill (dhill@arcweb.com) is Vice President and General Manager, Manufacturing Advisory Service, ARC.] www.arcweb.com
Allen-Bradley® Micro800™ Family of PLCs Plug-in, customise and expand for seamless performance The Micro800™ Family of PLCs gives you the best of both worlds with standalone functionality and component capabilities. Together with the Connected Components Workbench™ Software, you get: • Just enough control • Convenience and connectivity • One software • Part of the Connected Components bundle • Easy to install and maintain The Micro800™ Family of PLCs Outstanding solutions made outstandingly simple www.rockwellautomation.com.au
NEW PRODUCTS
Transmitters with switching functions NOSHOK Electronic Indicating Pressure and Temperature Transmitter/Switches provide local monitoring, 4-20mA current output and switching control. The 800/810 Series utilise ceramic or thin film sensors to deliver a high level of repeatability and durability. They also provide continuous monitoring and allow the programming of set points without pressurising. Applications include hydraulic and pneumatic systems, moulding and extruding equipment, stamping and forming presses, pumps and compressors, HVAC, power generation, transportation equipment and marine. The 850 Series utilises PT100 technology to provide continuous temperature monitoring, electronic temperature switching, and transmission of analogue output of 4-20mA while providing local digital indication. It allows for one or two switching outputs as well as an optional analogue output. A wide measuring range (between -200°C and 600°C) covers the majority of temperature measuring and switching applications AMS Instrumentation & Calibration 03 9017 8225 / sales@ams-ic.com.au
Micro USB Coupler
Tooling calculator A calculator for evaluating bending machine tooling is now available for the iPhone. The calculator enables users to determine the tooling needed for performing a particular bending task on any type or make of tube bender. By entering the bend radius, tube diameter and wall thickness users can instantly gain a clear visual representation of the type of mandrel and wiper die they will need to employ to achieve a perfect bend. Under development are user-selectable tube profiles and material types, such as steel, stainless steel and copper which will facilitate machinespecific calculations such as bending force requirements. Version 1.0 of the calculator can be downloaded free of charge from the iTunes App Store. Unison apps@unisonltd.com www.unisonltd.com
Weidmuller, has added to its FrontCom Micro range with the USB-A to USB-B coupler. The FrontCom Micro range is a panel mount IP65 protected communications port that is fixed to a 22.5 mm hole. The range allows technicians to access PLCs, drives and HMIs located in switchboards and cabinets for routine maintenance, reprogramming and upgrading without the need to expose themselves to high voltage equipment. Other models include a USB-A to USB-A coupler and RJ45/RJ45 coupler or RJ45/Ethernet IDC connection. Weidmuller 1800 739 988 / info@weidmuller.com.au
Leverage the advantages of GigE Vision The GigE Vision-compliant interface board provides digital, uncompressed image data directly to PC or network. It is compatible with the Sony FCB-EX E OEM series of cameras and may be integrated into customer applications. The interface board allows full control of the feature-rich FCB camera modules as well as providing compatibility with many software packages. With the advantage of the extra Cat5 cable length, the CVX FGI - FCB GigE interface board enables users to take advantage of the camera’s progressive scan sensor effectively doubling the effective resolution compared to previous interlaced versions of the cameras. Adept Electronic Solutions 08 9242 5411 / adept@adept.net.au
Hiquel PSL 1M Power Supply The Hiquel PSL 1M Power Supply is a 24Vdc single-phase power supply for 45mm DIN-rail mounting. The power supply is designed for small distribution boards, distribution boxes and applications in industrial distribution boards where a low profile is required. 12Vdc and 5Vdc units are available on request. Automated Control Engineering 02 4954 5004 / sales@aceg.com.au
Cable Float Switch can activate electrical components The Series CFS2 Cable Float Switch is a mechanically actuated floating switch intended to activate electrical components, usually pumps, to start and stop automatically. The CFS2 is suitable for simple level control of liquids for filling or draining reservoirs and tanks. Float switches such as the CFS2 are typically used for pump automation. Counterweights and cable hangers are available to suit a 8 www.pacetoday.com.au AUGUST 2011
variety of mounting applications. Optional cables available include those with UL/CSA approval, higher chemical compatibility, high temperature durability, oil resistance, and drinking water suitability. The CFS2 features a mercuryfree microswitch housed in an entirely waterproof casing made of polypropylene. Dwyer Instruments 02 4272 2055 / www.dwyer-inst.com.au
IN FOCUS
Cut emissions and boost profitability Companies must embrace an integrated approach to reducing energy operating costs and emissions and sustaining energy performance, writes Francisco Alanis.
S
ITE Energy Management can be broken down into two key areas: (a) reducing energy demand and consumption, and (b) reducing the supply costs of the energy used. An effective energy management plan must address both sides of this energy equation simultaneously. The supply side includes public utilities and the site’s utility plant; we will just call this ‘utilities’ for short. The demand or consumption side includes all production processes and operations that consume fuel, steam and power. Figure 1 illustrates a simplified layout of a typical industrial site. Energy Demand & Consumption. The production units usually require steam at different pressure levels, as well as fuel and power. Steam is used for heating, stripping and tracing. >
FIGURE 1: A typical industrial site’s supply and demand sides.
AUGUST 2011 www.pacetoday.com.au 9
IN FOCUS
FIGURE 2: Overview of the online Energy Management and Optimisation system.
By implementing an energy management programme with elements focusing on both supply and demand organisations can achieve significant returns – sometimes over 15 per cent of their annual energy costs with very attractive payback on the capital invested. Fuel is used in fired heaters. Power is required by pumps and compressors. These power requirements can be supplied by electric motors and/ or steam turbine drives. Energy Supply. The site’s utility system provides the utilities the production units require. High Pressure steam (HP) is usually generated in steam boilers. Where gas turbines are installed, HP steam is also generated in Heat Recovery Steam Generators (HRSG) to recovery heat available from the exhaust of the gas turbine. Medium and Low Pressure steam 10 www.pacetoday.com.au AUGUST 2011
(MP, LP) is generated by letting down HP and/or MP steam through steam turbines. Let down stations between steam headers balance steam requirements. The steam generation boilers can usually burn fuel oil, fuel gas or both. Power is usually generated in steam turbines. These could be steam turbines that drive rotating equipment (pumps and compressors) or steam turbogenerators that generate power and may include back pressure and condensing stages. Power can also be generated in gas turbines. Power can be imported (or exported) from the grid to close the site’s power balance.
Supply-Side Energy Management The goal in the utilities side is to reliably generate the energy the processes require in the least expensive and most efficient way possible. Fuels consumption and electricity import/export define the utilities operating costs. The following operating decisions will have the major impact on fuels use and power import/export: • Choice of boilers and their loads (boiler load allocation) • Choice of power generation turbines and their load (power load allocation) • Choice of fuels
• Choice of drives (motor or turbine) Additionally, system constraints and fuels and electricity contracts will also impact final operating costs and emissions. System constraints may include boiler hot standby requirements, boiler capacity as a function of fuel used, fuel mix ratios, emissions limits, and equipment items that must be on because of reliability. Energy contracts may include minimum and maximum rates, take or pay clauses, penalties, and hourly tariffs. As a result, finding the optimum equipment set up to achieve lowest oper-
ating cost requires a system that takes into account equipment performance as a function of load, equipment interactions, system constraints and energy contracts. A model-centric system like AspenTech’s Energy Management and Optimisation (EM&O) meets the above requirements.
Applications and benefits Benefits can be realised through a variety of ways. The main opportunities can be broken down into two main tasks: operational and strategic. Operational opportunities include:
FIGURE 3: Overview of the offline Energy Management and Optimisation system.
SNAPSHOT
INTEGRATED SOLUTION The integrated approach to energy management considers both the steam and power utility system and the production processes. An important component of the solution is provided by a rigorous modelbased energy management system, which can be used to help take advantage of potential savings which have hitherto been largely unexploited in addition to providing optimised and consistent information about a site’s key processes and facilities for decision-makers. This knowledge can be useful both in long-term, strategic decisions and in concluding energy supply contracts, in preparing budgets and in drawing up investment plans, as well as in optimising the energy costs of ongoing operations in real time, online optimisation based on current operation, utilities demands, costs and plant availability.
• Maximising use of most efficient equipment items • Correct choice and use of fuels • Correct choice of drives • Reduced hot standby • Reduce venting of steam • Better cost accountancy • Better adherence to contract terms and reduced penalties Strategic opportunities include: • Better purchasing – lower contract price and more reliable nominations • Emissions forecasts • Optimum scheduling of maintenance • Reduced capital investment for
improvements in energy efficiency The operational benefits are achievable through the online functionality of the EM&O system. This allows optimisation of the utility system in real time by identifying the lowest cost solution taking into account current changes in utilities demands, fuel and electricity prices, equipment availability and system constraints. It also allows the real time monitoring of equipment performance, emissions, and other key performance indicators. An overview of the online architecture is provided in Figure 2. The strategic benefits are achievable through the offline functionality of the EM&O system. This allows performing multi-period optimisation and “What-If” analyses to identify the best (short to long term) schemes in response to seasonal fluctuations and site changes. Cost savings in the 2-5% range have
been made by the applications outlined above with no capital expenditure other than software and dedicated servers or desk top computers. Cost savings in the 10-20% range have been made with relatively low capital expenditure on simple changes to the process design of the production units.
To achieve these goals, simple data visualisation is not enough, but dashboard display of information synthesised via operating models from real-time data. Energy management must be proactive and become part of the site operations.
Conclusions
AspenTech is a supplier of software that optimises process manufacturing. The company’s current flagship product is aspenONE v7, an application suite that enables process manufacturers to implement best practices for optimising engineering, manufacturing, and supply chain operations. [Francisco Alanis (francisco.alanis@aspentech.com) is Senior Principal Consultant with AspenTech’s APAC services organisation.]
An effective energy management plan must be holistic, addressing both sides of the energy equation effectively and monitoring and optimising both the supply and demand sides simultaneously. They should be designed to sustain the gains as the plant evolves over time, as equipment ages and is modified, as product mix and loading changes. The most effective programs should include at their core, a rigorous model of the utility system as well as continuous improvement capabilities.
About AspenTech
AspenTech 03 9572 5544 www.aspentech.com
Now direct to you. Faster and smarter. Over 15,000 sensing, connectivity, interface and communications solutions are now available locally and direct from TURCK Australia. 1300-132-566 turck.com.au
©2011 TURCK, Inc.
SENSORS | NETWORKS/FIELDBUS | RFID | CONNECTIVITY | INTRINSIC SAFETY
AUGUST 2011 www.pacetoday.com.au 11
IN FOCUS
Innovative development made simple The greatest investment required when modelling the behaviour of a machine occurs at a very early phase of the development cycle but once done delivers numerous benefits, writes Philipp Wallner.
G
ROUNDBREAKING innovations have always been accompanied by the introduction of new development methods. Not only the products themselves, but also the corresponding development methods are subject to a constant process of change. The machine manufacturing industry seems to be the exception to this rule. The development cycles here have hardly changed in years. But why such a conservative approach? Is the market pressure in this industry any less than in other areas? Or have we already found the best possible development strategies, leaving no room for improvement? The first is certainly not true in times like these. The price pressure in machine manufacturing is higher than ever, and the only way to keep up with it is through distinctive innovations combined with efficient development cycles. The second question also has a clear answer. Terms such as model-based design, simulation, automatic code generation, rapid prototyping and hardware-in-theloop are already well-known in the automobile and aerospace industries, for example. It seems that there is potential here just waiting to be tapped by machine manufacturers. What better time for gaining new competitive advantages than now? Some especially innovative sectors, such as wind power, have already taken the decisive step. Now it would be hard to imagine an integrated development process without the methods described below.
Model-based design Model-based prototyping processes create the foundation for integrated, sustained development. Nevertheless, scepticism often wins out – the high initial cost for creating a model scares off many developers from making that first decisive step. Yet the simulation model of a machine plays a very important role. The success or failure of the model12 www.pacetoday.com.au AUGUST 2011
COST: The price pressure in machine manufacturing is higher than ever and the only way to keep up is through distinctive innovations combined with efficient development cycles.
based development process depends on it. In how much detail do the processes in the system need to be described? Where simplifications can be made? Unfortunately there is no blanket statement that can be made here. There's no question – the greatest investment required when modelling the behaviour of a machine occurs at a very early phase of the development cycle. Yet once this obstacle has been conquered and the system has been modelled effectively, a great number of advantages suddenly arise for the machine manufacturer. This development process not only adds depth to the manufacturer's knowledge of the machine, it also synthesizes expertise from multiple departments into one place. Unlike with binary data or even source code, simulation models
Simulation models are most often prepared graphically and are therefore to a great extent self-documenting. are most often prepared graphically, and are therefore to a great extent self-documenting. Once it is created, the model provides a sustainable foundation for future development and optimisation, which means the relatively high initial investment pays off quickly. Not to mention the additional methods avail-
COMMENCEMENT: The greatest investment is required when modelling the behaviour of a machine occurs at a very early phase.
able in the development process, such as simulation and automatic code generation – which easily take advantage of the model-based design approach.
Simulation A complete model of the system that illustrates the machine's processes in the greatest possible detail, is the basic requirement for creating useful simulations. Once this requirement is fulfilled, design errors can be detected and corrected in early design phases, based on the results of simulations, instead of later on when they represent a risk to the machines and operators. The later in the design process an error is detected, the more expensive it is for the machine manufacturer. In this way, simulation modules can contribute indirectly to cost savings. The reduced need for expensive physical prototypes and time-consuming testing also results in increased cost and time efficiency. Even after a machine series is manufactured and delivered, simulation models continue to be quite useful.
Hardware-in-the-loop simulations allow an industrial controller or an industrial PC to be quickly converted into a system simulator that emulates the behaviour of the actual system in real time. BRIDGE: This gap in the development process can be filled easily using automatic code generation.
They enable the manufacturer to react quickly and flexibly when market demands change and to test the effects of modifications to the machine or controller.
simulation come to an abrupt halt at this point. Yet the problem is mostly trivial – to implement the solution in a high-level language required by the industrial controller would simply be too timeconsuming. As a result, all the advantages that the developer gained through using model-based design and simulation models are negated when trying to
Automatic code generation Model-based design and simulation are one side of the coin – but implementing the created structures on the industrial hardware is the other. Some new developments that work perfectly in a
Advan-Touch: Out Of The Box, Install And Connect! ct!
rt Prices sta m o fr
implement them in the field. Or are they? This gap in the development process can be filled easily using automatic code generation. Almost like magic, system and controller models are transformed into finished software objects that can be transferred directly to the industrial controller. At least provided the right tool is used, which supports the user through >
!
$2, 600!! ex GST
Wonderware and Advantech are combining their leading products InTouch visualization and Windows XP Touch Panel Computers to provide the most cost effective SCADA/HMI TPC offering. This unique offering delivers pre-installed Operator Interface units that benefit users as follows: • • • • • •
Fully operational TPC options that are ready to be used Ranging from 64,128,256,500 & 1k Tags Avoid lengthy installation time and compatibility challenges Windows XP OS with full InTouch HMI functionality One development environment without any need for compilation or costly conversions Ideal add-on to existing SCADA or to replace old and antiquated hardware
Call AUGUST 2011 www.pacetoday.com.au 13
IN FOCUS
HIDDEN: The automatic code generation practically invisible if the right tool is used.
the entire process and makes the automatic code generation practically invisible. Just a few clicks in an existing Simulink model, and the B&R tool – Automation Studio Target for Simulink – automatically implements the respective software object on the controller. What is essential is that the behaviour of the automatically generated source code is absolutely identical to that of the simulation module.
Rapid prototyping Rapid prototyping and hardware-in-theloop are two terms that are closely related to model-based design. But what exactly do they mean? How can machine manufacturers profit from them? Once a model-based control algorithm has proven itself in the simulation, it should be transferred as quickly as possible to the target hardware for industrial use, where it can be given the final test under realistic realtime conditions. If automatic code generation is used here, this is called “rapid prototyping”. Construction of conventional physical prototypes involves additional costs and is time-consuming. Rapid prototyping, on the other hand, takes only a few moments and hardly any actions from the user – provided you're using the right tools. But, if control structures can be designed using system simulations and transferred to the industrial controller using automatic code genera14 www.pacetoday.com.au AUGUST 2011
tion, why shouldn't this also be possible for the system model itself? The industrial controller has come to be much more than a simple microprocessor. It is a powerful computer that is fully capable of handling complex system simulations in real-time. These “hardware-in-the-loop” simulations allow an industrial controller or an industrial PC to be quickly converted into a system simulator that emulates the behaviour of the actual system in real-time. The applications are numerous; a hardware-in-the-loop system can be used for training purposes or to safely test new controllers. It is also possible to operate it parallel to the physical system for early detection of errors.
Wind power In most areas of machine manufacturing, model-based design, simulation and automatic code generation are now slowly gaining importance, but in the wind power sector they are already common practice. To what do they owe this head start in the use of new development methods? Are the engineers in the wind power sector generally more innovative than their colleagues in other areas? Although many factors may play a role here, the actual main reason is obvious. More so than in other areas of classical machine manufacturing, the testing of new wind power technologies involves great risks
CHANGE: Using automatic code generation system and controller models are transformed into finished software objects.
for humans and the environment. Wind turbines are generally located near populated areas, which means that errors in controller design or in the performance of the machine could have fatal consequences. Test failures on a real turbine also result in exorbitant costs, which is a strong motivation to take advantage of model-based design and simulation models. Yet another reason for the use of innovative design methods is the fact that wind power is a relatively young industry that has only been on the
scene for a few years. The success speaks for itself. As the wind power sector focuses on creating a consistent workflow – from model-based design and simulation to automatic code generation – it continues to gain importance on the market. Innovative development methods are the key to success. [Philipp H. F. Wallner works in the area of systems and control technology at B&R.] DAANET www.daanet.com.au 1300 322 638
BEHIND THE SCENES
Solar power is no pipe dream ANU researchers prove that solar generated power is no longer a theoretical concept and could in fact provide significant amounts of clean energy, writes David Petrikas.
R
ESEARCHERS at the Australian National University (ANU) in Canberra, have proven that solar generated power is no longer a pipe dream and could pave the way to supplying the world with clean energy. A Solar Thermal Group led by Associate Professor Keith Lovegrove, has constructed the world’s largest solar collecting dish, and have been fine-tuning its ability to automatically track the sun and maximise the energy collected. The reflecting parabolic dish – measuring 25 metres in diameter – has 500 square metres of highly efficient purpose-built mirrors, which together collect enough energy to power a four cylinder steam engine driven purely by reflecting the sun’s rays onto a collector coil to convert water to steam. Plans are already afoot to build a pilot solar generating plant which will prove out the concept already demonstrated by the existing solar generator dish located on the ANU university campus in Acton, ACT. At the same time, the team behind ANU’s Solar Generator 4 or ‘SG4’ (so named as it is the fourth design of solar generating system they have constructed – each larger than the one before it) are realistic about their ambitions and see solar energy as complementing, rather than replacing, existing power generation technologies.
Efficient design Lead researcher, Greg Burgess, also sees other potential applications for superheated steam produced by reflected solar energy. Such is the intensity of energy generated by the dish’s efficient design that when concentrated it can melt through solid aluminium, stainless steel plate and even the hardest ceramic known to man. According to Burgess, the aim of the solar project was to demonstrate that solar generated electricity is viable on a commercial scale. To prove this, the researchers needed a dish design that
installing and testing the first steam generating receiver. Despite a shoestring budget over many years and continued uncertainties over government-sponsored solar programs, SG4 is now a reality and may ultimately leapfrog existing ‘solar trough’ technologies based on its superior efficiency, especially given any favourable moves in public policy to encourage greater uptake of alternate energy technologies. For example, the special low-iron curved mirrors are 94% reflective, optical and thermal efficiencies are also in the high 90s, which means that overall more than 80% of the collected sunlight is transferred to the superheated steam leaving the receiver.
Purlin style frame
SIZE MATTERS: Building fewer large dishes is more economic than building lots of smaller ones.
was optimised for cost effective mass production on a large scale. Their thinking is that building fewer, large dishes which can be replicated in the field, is more economic than building lots of smaller ones. The genesis of the project started in the early 70s, with a team lead by Stephen Kaneff and Peter Carden, both since retired. Their early work led to the construction of the White Cliffs solar power station in remote Northwest NSW, comprising 14 small 20 square
metre diameter dishes. Convinced the idea had merit, the team at ANU proceeded to scale up the solar generator, with the first “Big Dish” built in 1994 using commercially available spaceframe technology. The latest dish, SG4 was completed in June 2009 and since then a great deal of further effort and research by Burgess and others has gone into fine tuning the solar tracking, sourcing computer and communication components, testing optical performance and
The newest parabolic dish at ANU has also been made from freely available building materials and some custom made rolled sheet steel purlin style frame sections. The mirrors are also flexible enabling them to be bent to fit into the structure of the dish. Costs have been kept down through clever engineering, including using the mirror panels as an integral part of the structure to provide stiffness with less framework and thereby reducing costs and unnecessary weight. Also, each of the 380 individual mirrors is identical in shape, making them completely interchangeable. “The cost of everything has to be commercially viable, so we have designed the system to be massproduced, which will further reduce costs as soon as it is put into mass production,” Lovegrove, said. “For example, we designed and constructed a very accurate dish assembly jig which actually costs as much as a dish itself, so that the framework for hundreds of future dishes can be produced more affordably, making the prospect of solar energy generation more viable.” Just how accurate, is demonstrated by the fact that a 25 metre wide dish > AUGUST 2011 www.pacetoday.com.au 15
BEHIND THE SCENES
built using the special jig matches a perfect parabola to within a millimetre. This means many other identical dishes could be built and installed around the country with predictable results.
Perfect tracking The large parabolic dish is supported on a two axis tracking system which is continually pointed at they sun. The excellent optics and precise tracking control system means it achieves optimum efficiency at any time of the day and any time of the year. The entire system is controlled by a PLC SCADA system supplied by Yokogawa which computes precise sun position information to ensure millimetre perfect tracking of the sun. This accuracy has been built-into the FA-M3 PLC SCADA control system which has been provided to the university by Yokogawa Australia – a specialist in process control systems used in power stations, oil platforms, solar fields and processing plants. A water line runs up to the ‘target’ at the top of the collector and a coiled tube within superheats the water to steam. The steam travels back down a steam line and in turn drives a small steam engine and generator located in a small enclosure near the base of the dish; three-phase power is then put back into the grid. A second FA-M3 is used for the steam turbine control. Yokogawa’s FastTools software is also used for data logging and has the capability to handle additional automation such as putting the dish in a ‘parked’ position at night and to prevent damage in times of high winds. However, ANU now plans to transition from the FA-M3 to the new Yokogawa HSX10 for even greater efficiency. Future units could be cost-effectively controlled with the new HSX10, which is designed to automatically track the sun to ensure maximum efficiency of the solar reflecting dish.
Energy storage Unlike wind and photovoltaic solar systems – which only produce energy when the sun shines or wind blows – overseas experience shows concentrating solar thermal power systems have the potential for energy storage using molten potassium nitrate or similar salt ‘thermal batteries’. This would add to solar’s current ability to provide peak demand 16 www.pacetoday.com.au AUGUST 2011
POWER: The steam drives a small steam engine and generator located in a small enclosure near the base of the dish.
during daylight hours. “Even now the steam produced from the solar generator can drive the steam turbine for half an hour after the dish goes ‘off-sun’, just from the steam in the pipes. Adding storage would add to the flexibility of solar as an energy source,” Lovegrove said. Best of all, the technology can be easily integrated with existing coal-fired power stations as it produces steam – and could provide a ‘solar boost’ to the existing water-steam stream of the electricity generation cycle, according to Managing Director of Yokogawa Australia and New Zealand, John Hewitt. “The change to the power station would be largely limited to the frontend, which makes the prospect of ramping up with solar-supplemented power more plausible in the real world. Best of all solar power is produced during the bulk of peak demand – during daylight hours when business and commerce is operating and home air conditioners are switched on,” Hewitt said.
Paying for itself Lovegrove explained that although commercial scale concentrating solar plants would represent a significant upfront capital investment, the technology pays for itself over a lifetime of use, unlike conventional technologies, which had high operating costs over their lifetime, such as coal extraction, haulage and boiler maintenance costs. And because the ANU prototype is far more efficient than existing solar arrays in operation in parts of Europe (notably Spain) and the US, ANU’s design could help speed up the adoption of solar as a viable energy supplement to fossil fuelled plants. According to Lovegrove, typical ‘trough’ type solar fields produce about 50 times the concentration of normal sunlight onto a water tube to produce steam. “Our dish produces 2,000 times the concentration of the incident solar rays which gives you some idea of its efficiency.” “People don’t realise how ‘real’ the technology is, and haven’t latched onto the idea of concentrated power yet as
they are more used to the more established photovoltaic ‘solar’ power which has been around for a long time. “As an example, in a large system with an array of dishes all feeding steam to a single efficient large steam turbine, each dish of this size would contribute the production of around 100 kW when operating at full efficiency in full sunlight. Overseas experience has shown this is enough energy to power 50 homes and Lovegrove believes that in the future up to 100 advanced energyefficient homes could be powered by every dish. A solar field the size of the ACT could power the entire country,” Lovegrove said.
Smaller plants In addition to feeding into grid power, Lovegrove sees an opportunity for smaller concentrating solar plants in remote regions to power mines and provide energy to minerals processing plants and communities. For some years, a small scale solar dish field operated in White Cliffs to provide power to the small opal mining town.
Pressure Safety Valve Vent to Atmosphere Steam Silencer Vent to Atmosphere TT
PT
LEGEND: TT - Temperature Transmitter PT - Pressure Transmitter FT - Flow Transmitter TG - Temperature Gauge PG - Pressure Gauge
PT
TT
Rotary Joint 2
Rotary Joint 1
Receiver
Hot Coolant
PT TT
Cold Coolant Cooling Tower
Steam Trap
Rotary Joint 2
Condenser Steam Engine
Rotary Joint 1 PG FT
Feedwater Preheater
Feedwater Tank Feedwater Pump
MAPPED: Simplified piping and instrumentation diagram of the ANU Big Dish Steam system.
“ ProTrac measures reliably – even under extreme conditions.”
New from VEGA: the radiation-based instrument series, ProTrac. GREG BURGESS: The aim of the solar project is to demonstrate that solar generated electricity is viable on a commercial scale.
“As a clean energy source, solar energy is a natural complement to wind and based on our climate is more available and provides most of the energy when you need it. “And from a practical perspective it could be easily married to coal-fired power stations and provide raw energy to other emerging technologies such as gasification. “We see concentrated solar technology as the ideal transition from smaller diesel-fired power plants, with a comparatively small 100-dish solar field providing around 10 MW of power. “The medium term goal for the concentrating solar technologies is to make electricity for about the same cost
as wind, which is currently around 1012 cents a kilowatt/hour. While that’s around double the cost of conventional coal-fired power stations, it may prove to be cheaper than adding carbon capture and storage to existing coal-fired power stations,” Lovegrove said. Of course, the ultimate energy economics will be influenced by ruling government policy, with any moves to tax carbon impacting on fossil fuel power stations and tipping the economics more in favour of alternate energy sources in the future.
ProTrac delivers reliable measurements for level, density, mass flow or point level. Using four detector variants, ProTrac can solve the most difficult measuring problems – whether in extreme temperatures, high pressures or aggressive media. The system also provides additional security with integrated asset management. www.vega.com/au/innovation Phone: 1800 817 135
Yokogawa Australia 02 8870 1100 www.yokogawa.com.au AUGUST 2011 www.pacetoday.com.au 17
BEHIND THE SCENES
Video surveillance can be integrated Growing security requirements for critical infrastructure in SCADA industries requires operators to existing SCADA networks without hindering communications and bandwidth to the control centre,
V
IDEO surveillance has been around for many years, but in order to monitor remote assets dedicated communications infrastructure for the video signal is required and the associated costs are normally very high. In the traditional SCADA industries, such as water/wastewater, oil & gas, and power, it is common for customers to have field controllers or Remote Telemetry Units (RTUs), which monitor the signals from the process instruments making it possible to piggyback video over the existing communications infrastructure.
Additional dimension
Integrating video When existing SCADA systems have communication infrastructure in place, such as radio networks, the video
FIGURE 1: The SCADA display shows real-time data incorporated with video image of a pump station site.
cameras can be connected to local video server software and send video images to the SCADA computer when abnormal conditions occur. This way the SCADA network is not
³,GHDO IRU FRPPXQLFDWLRQ ³,G WWKURXJK KDUG WR UHDFK ORFDWLRQV RU ZLWK PRYLQJ OR LQVWDOODWLRQV ZKHUH FDEOHV LQV DUH QRW GHVLUDEOH ´
,1'8675,$/ (7+(51(7
18 www.pacetoday.com.au AUGUST 2011
used for continuous video stream and conserves bandwidth. When motion is detected an alarm is raised and the cameras record both image snapshots and video event clips
ZZZ DQ\EXV FRP DX
Regulatory compliance is also increasing, forcing customers to add video capability to monitor critical infrastructure and provide operators with an additional dimension in managing these processes. The American Water Works Association (AWWA) and Water Environmental Federation (WEF) have developed a three-phased program to address physical infrastructure security and video camera/CCTV is an obvious solution.
during the period of motion. Also, the video cameras can be setup with pan, tilt and zoom (PTZ) controls so that the operator can more efficiently investigate the alarm without
&RQQHFW \RXU HTXLSPHQW YLD %OXHWRRWK RU :/$1 $Q\EXV :LUHOHVV %ULGJH DOORZV LQGXVWULDO (WKHUQHW EDVHG HTXLSPHQW WR EH LQVWDOOHG ZLWK ZLUHOHVV WHFKQRORJ\ DQG PDNHV LW SRVVLEOH WR EULGJH SURWRFROV VXFK DV 3URÂżQHW (WKHU1HW ,3 DQG 0RGEXV 7&3 Ĺš :/$1 E * RU %OXHWRRWK Ĺš :/$1 DQG *+] YHUVLRQV Ĺš 0D[ UDQJH P RSHQ DLU
Ĺš 3XVK EXWWRQ FRQÂżJXUDWLRQ Ĺš ,QGXVWU\ FHUWLÂżHG
with SCADA efficiently integrate video surveillance into their writes Eric Schwantler.
having to physically be onsite. The SCADA display (Figure 1) shows real-time data incorporated with video image of a pump station site.
Remote security Control Microsystems has partnered with Longwatch, a provider of software to manage and integrate video with SCADA systems. The product combination provides a remote security solution allowing operations staff to monitor both the physical security of sites as well as the expected operation of the system.
Key components Figure 2 shows a typical solution configured for ClearSCADA. The system is made up of a number of key components: • Cameras supporting pan, tilt, and zoom. • The Longwatch video engine at each site to manage and buffer the real-time video. • ClearSCADA host computer with
It is not necessary to install dedicated IP links for video as video information can be transmitted to the host computer on the same links already existing for SCADA data. Video Control software for video archiving and alarm management.
Abnormal condition Field based cameras constantly record high resolution video at the remote site. When an abnormal condition occurs, an ‘event clip’ – which is typically lower resolution to accommodate the communications network limitations – is sent back to the control centre based on prede> termined triggers. AUGUST 2011 www.pacetoday.com.au 19
BEHIND THE SCENES
Your solution focussed partner for sensors and controls for automation
FIGURE 2: This shows a typical solution configured for ClearSCADA made up of a number of key components – cameras, video engine and host compute.
Video engine
1300 365 088 sales.au@ifm.com www.ifm.com
The high resolution video remains at the remote site and is stored within the remote video engine appliance. This mechanism also provides buffering in case the communications to the remote site is unavailable. Further to this, communications between the remote site and control room can utilise existing infrastructure. It is not necessary to install dedicated IP links for video as video information can be transmitted to the host computer on the same links already existing for SCADA data. Where system communications utilise slow links such as 9600 baud serial radios, video data can still be transmitted back to the central computer.
Industry standard ClearSCADA interfaces to the Video Control software using industry standard OPC. Therefore, points/tags can be configured to monitor for alarms, such as motion detection, used for pan, tilt and zoom (PTZ) control to move the cameras to pre-set positions, and to monitor parameters, such as communications bandwidth, video bit rates, etc. Once an alarm is detected, the operations staff can view the historical video clips and alarm information stored in the Video Control software. This provides the ability for video information captured from the remote site to be compared to control process information in the same time period, allowing operators to see if physical issues are related to process disturbances.
Greater visibility Surveillance of remote assets using video technology provides greater visibility of real-time conditions. When these assets are related to critical infrastructure, such as drinking water, pipelines, electrical substations, etc., and where governments around the world have mandated increased 20 www.pacetoday.com.au AUGUST 2011
monitoring, video surveillance is a natural and efficient solution. The Longwatch and ClearSCADA combination provides all the functionality to meet these requirements while minimising costs and implementation time by utilising existing SCADA networks.
About Control Microsystems In 2010, Schneider Electric acquired Control Microsystems as the latter’s product portfolio complemented and expanded Schneider Electric’s existing application fields. Michel Crochon, Executive Vice-President of Schneider Electric’s Industry business, noted that his company made the acquisition “to address the needs of the attractive water, wastewater and oil & gas industries for which remote monitoring and control are critical to their large and dispersed sites. Crochon noted: “The combination of technologies, channels, customer knowledge and complementary execution capabilities will put us in an excellent position to capture new opportunities in these fast growing markets.”
Challenging the market According to a report in ControlGlobal.com, by continuing to build its capabilities in upstream oil and gas, pipelines and utilities, Schneider Electric is challenging the major process automation vendors on territory which they themselves tend to see as peripheral to their core activities in refining, petrochem and chemicals based on their DCS capabilities. The approach is in intriguing contrast to that taken by other vendors seeking to expand into process. [Eric Schwantler is ClearSCADA Product Manager for Control Microsystems.] Control Microsystems Australia 03 9249 9562 www.schneider-electric.com
When Moore Industries—the #1 company in Alarm Trips—needs SIL 2 Functional Safety approval, we look to the #1 company in Safety Certifications—TÜV Rheinland. Our STA Safety Trip Alarm is your answer to back up your PLC or DCS “soft” alarms with 40 years of field proven “hard” alarm experience. Confidently use the STA as a safety logic solver to act on hazardous process conditions, provide emergency shutdown, and provide on/off control in Safety Instrumented Systems.
• Designed for use in Safety Instrumented Systems (SIS) up to SIL 2, and the firmware is suitable for a SIL 3 configuration. This allows use in a redundant architecture (1oo2, 2oo3, etc.) up to SIL 3. • The STA is provided with comprehensive TÜV Rheinland certified safety data to determine its applicability to specific safety related applications.
Get our NEW IEC 61508 White Paper To learn more about our STA Safety Trip Alarm, and to download our white paper, go to:
www.miinet.com/safetyseries
PHONE: 1800 784 899 • sales@mooreind.com.au
BEHIND THE SCENES
Rapid recovery for flood-hit pumps The South East Queensland flood affected huge areas of residential and rural land, including the Gatton operations of vegetable grower Barden Produce. Losses were large, but staff got the facility up and running again in a week, writes Matthew da Silva.
T
HE rain started in the Lockyer Valley west of Brisbane on Monday 10 January 2011 and rainfall, announced late the next morning by the Bureau of Meteorology, reached rates of 80 mm to 100 mm per hour. A second rain event occurred on Tuesday when floodwaters from Grantham and Toowoomba started to flow through the Lockyer Creek through Gatton. “Five minutes of no pump activation at a peak rain event can be a very significant issue,” says Allan Dall, divisional manager of Sydney processing operations with Barden Produce.
Submerged pumps Barden lost $500,000 worth of crops at Gatton, including 200,000 bunches of Asian vegetables at its five-acre hydroponic facility, when two submerged evacuation pumps stopped after energy supplier Energex cut the power supply. “They were actually working and controlling the flood until they cut the power to the town,” says Barden Produce national hydroponics manager Nathan Clackson. “When the power went, the farm went under in like two minutes.” Clackson was at home in Peats Ridge on the NSW Central Coast when the flood event occurred. “I was down here and I sent the farm manager back to turn [diesel generators] on,” says Clackson. “The police turned him around because they shut the road down.”
Controllers under water The pumping sheds, which feed the hydroponic tables, were flooded and recirculating pumps for the facility stopped operating. “It swamped controllers, pumps, electrics, generators, you name it,” says Dall. “Even the actual tables themselves, some of them were underwater.” Barden supplies major supermarkets 22 www.pacetoday.com.au AUGUST 2011
ACTIVE: Probes in the white box at top right feed pH and EC readings to the Bluelab Dosetronic controller, which controls the Peridoser dosing unit at bottom. There are six tanks and systems like this at Barden’s Gatton facility.
including Coles, Woolworths and Aldi, as well as independent customers. Produce was shipped from Barden’s Peats Ridge (NSW) hydroponic facility to maintain supply. “I built the farm, I knew exactly what we were missing, so I went to see my irrigation supplier,” says Clackson. His controls supplier is Thinkwater Irrigation. “They rang up Brown Brothers, who sells the pumps, and they got some flown in from overseas,” says Clackson. “I got them landed two days later. They
rang up Kenran and Kenran made me six new pump starters.”
SNAPSHOT
AUTOMATED CONTROL
Replacement gear Clackson drove to Queensland bringing replacement equipment in his car. “I got in what I could,” says Clackson. “What wasn’t in stock we flew in from overseas. “I got stuff delivered to me that Saturday lunchtime from suppliers and I drove up Sunday night from Sydney to Gatton and basically I reinstalled all the pumps and controllers over the next two
The Dosetronic provides continuous control of conductivity and pH levels of a solution by adding fertiliser and pH corrector into the mixing tank via peristaltic pumps or solenoids. Simply program the controller with the desired conductivity and pH values and tailor the dosing intervals to suit the size of the mixing tank.
says Dall. “Obviously there’s a small delay from the time that you a dd the dose of nutrient into the tank and when [the reading] comes back to the doser.�
The flowmeter senses whether or not water is moving in the system and can alert our farm manager if there is an issue either in partial obstruction to the flow or whole obstruction to the flow. days and got the farm running again,� he says. “While I was doing that we had some labourers cleaning the farm down, getting rid of all the mud using pressure cleaners and all that sort of business, to fix it all up,� Clackson says. “From a capital investment perspective, every hole here in this facility costs us money every day,� says Dall. “If there’s nothing in it we’re not making any money. “From a fulfilment of customer orders [perspective] – commitments that they’ve given us for volumes that we have to deliver – if we’re not planting into these holes in four to six weeks we’re not going to have crop available to supply to those customers, to [meet] those commitments.� Dosetronic dosing controllers and Peridoser dosing units were flown in from manufacturer Bluelab in
Three solutions
MANAGED: Barden Produce operates a five-acre hydroponic facility at Gatton, Queensland and supplies major supermarkets as well as independent customers.
New Zealand. “Bluelab responded pretty quickly to me needing dosers and sent them straight over,� says Clackson. Barden’s flowmeters provide an indication of the volume of tank water – which is dosed with nutrient solution, acid solution and alkali solution – being transferred back to the hydroponic tables. The tanks hold 5,000 litres each and there are six tanks, three in each shed.
The flowmeter senses whether or not water is moving in the system. “It can alert our farm manager if there is an issue either in partial obstruction to the flow or whole obstruction to the flow,� says Dall.
Small delay Probes from Bluelab take a measurement of pH and electrical conductivity and the output. “It’s taken every 30 seconds,�
The signal is fed to the Dosetronic unit that controls the Peridoser unit, which dispenses the three solutions into the storage tank. “Our priority was, being that there’s six systems, to get three operational,� says Dall. Staff were planting seedlings at the hydroponic facility a week after the flood event. “I had half the farm going in the first day and the other half the second day,� says Clackson. “At the end of the second day we planted a heap of seedlings and caught up on what we missed out on. “We were harvesting our crops before other farmers could get onto the ground that they had for field growing.� Barden now has a failover system in place in the form of a manual diesel pump that can supplement the two evacuation pumps. “That gives us the opportunity where, if the pumps and the controls fail on that rainwater evacuation, we’ve got a secondary option to try to maintain that, and reduce the water that’s there before it floods the pumping shed in future,� says Dall. Think Water Peats Ridge 02 4373 1466 www.thinkwater.com.au
7HVW *DXJH .LWV $YDLODEOH ZLWK RU JDXJHV $FFXUDF\ DQG FDOLEUDWLRQ VHUYLFH DYDLODEOH 3UHVVXUH WHVWLQJ IURP EDU WR EDU 3UHFLVH FRQWURO DQG PRQLWRULQJ 0DGH LQ *HUPDQ\ +RZ GRHV \RXU HTXLSPHQW PHDVXUH XS" HQW PHDVVXUH XS"
ZZZ K\GDF FRP DX
AUGUST 2011 www.pacetoday.com.au 23
BEHIND THE SCENES
Benefits
of energy efficient
technology
The State Library of Victoria achieved significant reductions in energy consumption. The new setup in the 150-year old heritage listed building slashed power bills and achieved payback in months, writes Hartley Henderson. gy 40 CO2 emissions (Gigatonnes)
57% Current trend
20%
30
Energy efficiency
Renewables Biofuels (3%)
10% 10%
450 Policy Scenario
Nuclear CCS*
*Carbon capture and storage
20
2000
O
2007
2020
VER the last ten years the push for energy efficiency has been rapidly gathering momentum, particularly in relation to productivity improvement and reduction of carbon emissions. During a recent visit to Australia from Low Voltage Drives headquarters in Finland, ABB group vice president, Pekka Tiitinen, pointed out that 65 percent of all energy consumption at industrial sites goes through motors, and that the biggest challenge is ignorance of the scope for savings. ABB is considered a world leader in the development of energy efficient motors, drives and control systems. “Some 50 percent of carbon reduction comes
24 www.pacetoday.com.au AUGUST 2011
2030
SAVINGS: The main source of potential emissions reductions. (Graphic courtesy: ABB)
from energy efficiency improvement from renewable energy and other non-fossil, plus carbon capture storage,” he said. “Australia is a front runner in legislating for energy efficiency and recognising the benefits of energy appraisals for industry and large buildings. In industry, cost/benefit analysis demonstrates that big savings of up to 50 percent can be achieved, with payback typically in one to two years and sometimes even five to eight months. “The easiest way to add more electricity capacity, is to improve the energy efficiency that would release existing capture in new consumption. Nowadays, more and > more systems are playing a key vital role in that.”
Gearmotors \ Industrial Gear Units \ Drive Electronics \ Decentralised Technology \ Drive Automation \ Services
Servo Drive Systems from SEW-EURODRIVE Precise automation solutions Microcalligraphy on rice grains is an ancient eastern tradition which requires immense concentration, neatness of hand and keen eyesight. In the modern day precise tasks such as this are accomplished with technology. SEW-EURODRIVE offers a modular servo and automation system for just this reason. We supply complete automation solutions based around our range of synchronous rotary & linear servomotors, precise gear units, linear electric cylinders, frequency inverters, PLCs & motion controllers. Combined, we can engineer these components to provide exact position control for single or multiple axis applications in order to meet even the most demanding automation challenges.
1300 SEW AUS Melbourne (HQ) I Sydney I Adelaide I Perth I Brisbane I Townsville
www.sew-eurodrive.com.au
BEHIND THE SCENES
Energy saving technology
JUSSI RAUTEE: The same flow was produced without throttling but by reducing motor speed.
26 www.pacetoday.com.au AUGUST 2011
According to ABB’s senior vice president in Australia, Jussi Rautee, significant productivity improvement and environmental benefits are being achieved in Australia through conduct of energy appraisals and the installation of energy saving technology. The State Library of Victoria was founded in 1854 and is a reference and research library for over one million visitors a year. It holds more than two million books and occupies an entire city block of two hectares, comprising reading rooms, galleries, exhibition spaces, conference centre and cafe. Jussi says that an energy appraisal carried out at the library concluded that significant energy savings could be made by replacing the existing HVAC flow control, which used throttling valves, with variable speed drives. “The library has four water-cooled chillers with eight motors ranging from 15 to 55 kW; five cooling tower fans with one 11 kW motor each; and two
Precise AC drive control provides more accurate fan control in the cooling towers and has significantly cut noise pollution from the fans thereby eliminating disturbance for library visitors. gas-fired heating boilers with one 22 kW and one 30 kW motor on the hot water circulation pumps,” he said. “The chillers were running with 50 to 60 percent throttling at the discharge end, as well as across the evaporator and condenser vessels. Now, the same flow is produced without throttling but with motor speed reduced to between 75 percent and 90 percent of full speed.
“In addition, the five cooling tower fans were controlled by continuous starting and stopping of the single speed motors, running approximately five minutes each. These motors now run continuously at approximately 50 percent speed.”
Significant benefits Jussi advises that by using 15 ABB standard drives for HVAC, from 5.5 kW to 55 kW, energy savings of between 30 to 60 percent were achieved across the various applications. “With combined motor ratings of 400 kW and 24/7 plant operation, the total energy consumption was reduced by 1,800 MWh annually, saving the library nearly $60,000 per year. Payback, including maintenance savings, was achieved in just 14 months,” he said. “It should be pointed out that oversizing is the norm in most HVAC installations. The expected load is usually known when the system is designed. However, there are many other factors that are not known, such as the resist-
STATELY: The State Library of Victoria occupies an entire city block of two hectares.
ance of the new pipe work. “Also, users often want to allow for possible future expansion. For these reasons, specifiers tend to design systems slightly larger than needed. However, an oversized HVAC system uses more energy than is needed to control the indoor climate. “The variable speed drive can give the over-capacity back to you in the form of energy savings, instead of wasting the excess energy through the use of throttling valves. The installation of drives optimises the energy performance.� Mike Brown, maintenance engineer at the State Library of Victoria, says he was surprised by the large savings that
could be achieved by reducing the speed of fan and pump motors by just a little. “In the past we only used AC drives to control speed when we wanted a specific flow rate. Through the energy appraisal, I became aware that great energy savings could be achieved as well,� he said.
Improved efficiencies “Working with energy efficiency can be a challenge in an old building. No matter how hard we try to raise efficiency, it will never match a modern building. The library is 150 years old and heritage listed,� said Brown. “Its large halls with high ceilings
make it difficult to air-condition. Some of the walls are a metre thick which makes it hard to achieve the desired temperature. “Under these conditions, using AC drives is a useful way to save energy where we can. It also helps us control conditions accurately – the temperature needs to be controlled to 22 degrees and the humidity to 50 percent to protect manuscripts, paintings, and the two million books in the library. “The system has exceeded expectations. It has been very reliable and produced massive savings in energy and maintenance that will be reaped in the coming years.�
In summary, the introduction of AC drives has eliminated energy waste caused by oversizing of the existing HVAC system and subsequent throttling, and has delivered substantial improved efficiencies. For example, the accurate pump speed control offered by the AC drives has improved the chiller compressor’s efficiency. For each degree the return water temperature deviates from the design temperature, the compressor becomes 1.5 percent less efficient. Circulating cooling water at the optimum speed means less energy is needed to run the compressor. Also, precise AC drive control provides more accurate fan control in the cooling towers and has significantly cut noise pollution from the fans, thereby eliminating disturbance for library visitors and improving living conditions in nearby residential blocks. In addition, maintenance is reduced compared to stop-start control, as the drives’ soft-starting reduces wear of motor bearings and fan belts.
About ABB ABB operates in more than 100 countries, with over 124,000 people worldwide. The company considers itself a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact. To address environmental standards, ABB has adopted ISO 14001 as their environmental management system standard. ABB Australia Pty Limited www.abbaustralia.com.au www.abb.com/drives
The Most Complete Range of Planetary Gearheads Â? Stocked
in Australia - supported ported worldwide motor brands Â? Suit all servo and stepper motor Design Tool Â? Easy selec on with online DesignTool
Â? Online drawings and
Â? IP67
Â? Stainless steel
� True Helical Technology � 100% Maintenance-free � Two year warranty Thinking “inside� the Box � Quiet
www.apexdyna.com.au
h ts 1 MA mm las n men E i k c : N p e 80 00 ba ic & 3 - 2 Dro eplac w r .5 - 5 t o L
R 1 Me izes 1 s
APEX DYNAMICS AUSTRALIA 36 Taunton Drv Cheltenham VIC 3192 Tel: +61 3 9585 2739 sales@apexdyna.com.au
Quality Value Delivery
AUGUST 2011 www.pacetoday.com.au 27
SPOTLIGHT
7best of the
PACE showcase of the best engineering technology releases of the month.
Tester diagnoses problems The handheld Fluke 810 Vibration Tester enables maintenance teams to rapidly collect data and diagnose and solve mechanical problems. It is designed and programmed to diagnose common mechanical problems of unbalance, looseness, misalignment and bearing failures in a wide variety of mechanical equipment, including motors, fans, blowers, belts and chain drives, gearboxes, couplings, pumps, compressors, closed coupled machines and spindles. When it detects a fault, the tester identifies the problem and rates its severity on a four-level scale to help the maintenance professional prioritise maintenance tasks, and recommends repairs. Context-sensitive on-board help menus provide new users with real-time guidance and tips. It uses a simple step-by-step process to report on machine faults the first time measurements are taken, without prior measurement history. Fluke Australia 02 8850 3333 sales@fluke.com.au
Precision range of wireless instruments Yokogawa has released its precision range of wireless instruments, offering accuracy and reliability, with built-in futureproofing. The wireless pressure, differential pressure and temperature sensors are suitable for large and widely spaced plant equipment and challenges presented by moving equipment such as rotating kilns. These wireless instruments provide accurate transmission of data with virtual zero bit rate error up to 600m, without rqeuiring special antennas. They eliminate the need for cable runs and support multiple indus-
trial protocols – HART, Profibus, Modbus and Foundation Fieldbus. New instruments can be quickly installed and integrated into the network. The ISA100.11a standard employed in Yokogawa wireless instruments talks to all other certified ISA100.11a devices. Yokogawa’s ISA100.11a wireless products provide unlimited networking capabilities using IPv6 which supports an almost infinite number of addresses. Yokogawa Australia 02 8870 1100 inquiries@au.yokogawa.com
Reliable thermal dispersion flow switch The Gems FS-600 Series from Control Components is a robust, ‘no moving parts’ flow switch that works with both conductive and non-conductive fluids. The solid-state sensor is immune to changes in viscosity and is suitable for clean fluids and some slurries. The FS-600 uses the cooling effect of a flowing fluid or gas (calorimetric principle) to monitor the flow rate. This temperature-based operating principle can reliably sense the flow of virtually any liquid or gas without using any moving parts. The affordable FS-600 can thus provide years of reliable, worry-free operation even in applications without filtra28 www.pacetoday.com.au AUGUST 2011
tion. The FS-600 is made from durable stainless steel and is available in various housings to suit a wide variety of pipe sizes for flow rates from 0.5 LPM to 41 LPM. All models have an IP65 M12 electrical termination and include a 1 metre cable assembly. Longer cable assemblies are available. The port sizes are between 1/2" to 1-1/2" The straight-through switch is designed for a long life and can be mounted in any orientation. Control Components 02 9542 8977 www.controlcomponents.com.au
Email your product news to pace@reedbusiness.com.au
HYDAC Test Gauge Available with one, two or three gauges, HYDAC Test Gauge Kits offer accurate, precise and efficient pressure control and monitoring for your hydraulic system, while eliminating the risk of introducing contamination. The kits, made in Germany, are pre-packaged with quality HYDAC gauges, adapters and test couplings that are designed to be precise as well as durable. Interchangeable with all competitor test point versions and capable of pressure testing on any machine the kits are a must have for every mobile service engineer. HYDAC 1300 449 322 info@hydac.com.au
Bubble detector for liquids Sensirion’s LG01 micro flow switch has applications in ultra-low liquid flow rates and bubble detection. The sensor makes fluidic systems more reliable by enabling the detection of liquid flow within the range of a few ml/min and less. For such measurements the sensor offers a short response time below 100 ms. Its output signal of either 0 or 5V indicates whether the current flow rate is above or below the specified flow switch level. At continuous flow rates above this limit the identification of air bubbles within the
flow channel is equally consistent. Maximum flow rates are accepted up to 220 ml/min. Fluidic connections can be made via 28 standard fittings, suitable for connecting plastic tubing with outer diameters of 3.2 mm or 1.6 mm. The tiny, light sensor is designed for integration into bio-medical applications and general process control solutions. Sensirion jennifer.wagner@sensirion.com www.sensirion.com
Controller family cuts acquisition costs Machine builders and end users who need a cost-effective control solution for small applications may consider the family of Allen-Bradley Micro800 component-class micro programmable controllers and Connected Components Workbench software. Together, the controllers and software are easy-to-configure, install and maintain. Designed to be used with other AllenBradley component class products, such as drives, motion control and interface modules, the controllers are part of a solution bundle that offers machine builders easy selection, installation and commissioning of their standalone machines. It is suited for standalone machine applications with fewer than 48 I/O.
Leveraging the controller’s embedded USB and serial ports, machine builders can program the controllers and link them to HMI and other serial devices. Rockwell Automation 03 9896 0300 www.rockwellautomation.com.au
Pipeline and wellhead testing for vessels The DH-Budenberg Figure 80 deadweight testers provide accurate measurement for pipes and vessels. Due to its purely mechanical operation, the tester may also be operated in hazardous areas. The unit features an integral large precision mechanical pressure gauge. Applications for the Figure 80 deadweight tester include: Wellheads, where it measures well head gas pressure and hydraulic test pressures of riser pipes; Gas Terminals, where it monitors gas pressures associated
with flow metering; On Pipelines, where it measures pressures on leak and yield testing as well as frictional pressure losses. In thermal power stations it is used to accurately measure steam pressures for efficiency testing. Four versions are available, with pressure ranges up to 800 bar. DH-Budenberg 08 9562 7150 www.dh-budenberg.com.au AUGUST 2011 www.pacetoday.com.au 29
EVENTS & EDUCATION
WHAT’S ON
REVIEW
Learning and Applying SolidWorks 2011 - 2012
Inaco Technology Tour 4 August 2011, Toowomba www.inaco.com.au SCADA Systems Australia 9-10 August 2011, Brisbane www.scadaaustralia.com.au IICA Technology Expo 10 August 2011, Werribee www.iica.org.au IICA/ISA (EI10C) Industriall Flow Measurement Overview 11 August 2011, Melbourne www.iica.org.au Qld Gas Conference and Exhibition 16 August 2011, Brisbane www.jktech.com.au International Desalination Associattion World Congress 4-9 September 2011, Perth www.idadesal.org
For daily updates visit www.pacetoday.com.au
Learning and Applying SolidWorks 2011-2012 By L. Scott Hansen Industrial Press $52.95 This unique reference is intended to help users learn SolidWorks on their own with little or no outside help. Unlike other books of its kind, it begins at a very basic level and ends at a fairly advanced level. It has been updated to include all new features of SolidWorks 2010 - 2011. It is perfect for anyone enrolled in Engineering and Technology programs, as well as professionals interested in learning
GIVE
AWAY
SolidWorks. The book provides instructions along with illustrations. Commands are shown in bold for those who prefer not to read every word of instruction.
Programmable Automation Technologies: An Introduction to CNC, Robotics and PLCs Daniel E. Kandray Industrial Press $93.95 Divided into four parts, Programmable Automation focuses on programmable automation technologies used in industry. Comprehensive yet concise, this unique textbook provides a solid foundation of analytical techniques to justify automation and the knowledge and instruction of how to program CNC equipment, industrial robots and PLCs. Through a very prac-
tical approach, readers will learn specific programming languages related to each technology including G code and ladder logic. And it is sure to be found useful by interested in learning about programmable automation.
You could win one of these books by answering the following question: On which page of this magazine will you find “www.isc-ltd.com” mentioned? Email your answer to kevin.gomez@reedbusiness.com.au
Both books are available direct from Elsevier Australia Customer Service, 1800 263 951 or customerserviceau@elsevier.com
IICA NEWS & VIEWS
World-class training available in Australia ISA courses provide practical skills in a vendor-neutral format, writes Graham Moss.
T
WO non-profit industry groups representing the process control and automation community have got together to present practical and valuable training in Australia. IICA, the Institute of Instrumentation Control and Automation, represents the whole control and automation community in Australia – engineering and trade personnel, enduser organisations, vendors and the educators in our industry, and has been doing this for over 60 years. ISA, the International Society of Automation, is a similar but much larger international organisation based in America. Over the past couple of decades, ISA has developed an internationally recognised training program 30 www.pacetoday.com.au AUGUST 2011
targeting process control and automation technologies. IICA instructors are now presenting the ISA training in Australia. Why? And what is different about ISA’s training? Instrumentation, process control and automation has always had a high element of on-the-job training. This is true of all areas of engineering, however more so for control and automation because of its narrow application areas. Practical skills have traditionally been acquired from experienced superiors on the job. But the numbers of experienced engineers and technicians in industry have dropped considerably in the past couple of decades as companies have reduced manning and outsourced engi-
neering services. The experience-pool has become concentrated in the support departments of large vendors – and an increasing proportion of this support is now overseas. The ISA training courses provide these practical skills in a vendorneutral format. The courses have been developed by practitioners with specialist plant experience. The courses are continuously updated for new technologies and products. The ISA courses are now provided in over 30 countries around the world by ISA and their partners such as IICA. The IICA instructors are selected for practical experience in their fields and are accredited by ISA for each specific course. IICA’s program covers both introductory topics as well as new technology
areas. We presently provide courses on 10 subjects, with practical information on basic subjects such as selecting different flowmeters for different plant conditions or debunking the mystery of effective grounding and surge protection. We also provide courses on advanced topics such as the latest wireless and fieldbus technologies. In the last couple of years, IICA has run over 60 courses and feedback has been excellent. There is a large degree of interaction between the participants and discussion of real problems experienced in control and automation applications. [Graham Moss is IICA Training Manager.] www.iica.org.au/info/education 1300 781 715
Want to win a trip to Hawaii? Simply tell us want you want to read about by taking our survey at pacetoday.com.au/hawaii.aspx and you are in the draw*!
Prize includes: • Return economy flights for two adults from your nearest capital city to Honolulu, Hawaii*
• 7 nights accommodation at one of Aqua’s Hotels and Resorts*
*Terms and Conditions apply. Vist http://reedbusiness.com.au/hawaii_terms.pdf to view T&C’s. Authorised under NSW Permit No. LPTS/10/12040, VIC Permit No. 10/4457, SA Permit No. T10/2999, ACT Permit No. TP10/05480.1.
“Not another PLC!” That is exactly what the ABB AC500 and AC500-eCo PLCs are. Not like any other PLC
A uniquely scalable concept Investment saving Time saving Cost saving
If you would like to know more about this unique product, or any of our ABB offerings, please contact us for more information or a demonstration.
High Technology Control Pty Ltd 8 Stuart Street, Padstow, NSW, 2211 Phone: 02 9771 4088 Fax: 02 9772 3854 www.hightech.com.au email: mjlinden@hightech.com.au
HTC High Technology Control