PACE - Process & Control Engineering - December 2011 by Prime Creative Media

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www.pacetoday.com.au

PACE PROCESS & CONTROL ENGINEERING

Advanced automation Manufacturing can take advantage of the benefits of integrated architecture. Special Report 6

HMI platforms evolve They are now a primary building block for automation systems. Opinion 8

Mission critical networks BARRON GJM Pty. Ltd. P.O. Box 792 • Artarmon NSW 1570 Tel. +61 294361088 • info@barron.com.au

DECEMBER 2011

VOL.64 NO.11

INSIDE THIS ISSUE OF: OFFICIAL MAGAZINE

INSIDE THIS ISSUE

Technology Report 9

Early detection is key Advanced diagnostics in a pressure transmitter can detect integrity issues in the electrical loop between transmitter and host. Case Study 26

Boosting productivity Automation implemented at an aluminium pre-treatment plant results in doubling of production output. IICA News & Views 30

Post Print Approved PP255003/00539

Solutions Expos 2012 Expos will feature short presentations detailing solutions to specific problems rather than a sales spiel.

BY ISAAC LEUNG BELDEN recently ran its Hirschmann 2011 Mission Critical Network Design Seminar on the Gold Coast. The event represented the first such seminar held by Belden in Australia. Belden, through its acquisition of Hirschmann in 2007, and GarrettCom in 2010, is now considered a leader in the industrial networking segment with 35 percent market share. The seminar covered the three platforms on which Belden runs: cable, connectivity and networking. The sessions were presented by Belden and Hirschmann application engineers, technical support, competency centre managers and product managers flown in from Singapore, China and Germany. Belden’s Asia Pacific vice president of sales and marketing Keith Mauck pointed out that given the organisers only had six weeks to market the seminar, the turnout was exceptional, especially since the team had hoped for 40 attendees. “We decided at the last minute that I wanted to do it this year rather than waiting,” Mauck explained. “I wanted to do it, but I didn't have it in the plan until we saw that our earlier seminar in Bangkok was successful. The feedback was very positive, and the team here indicated that we could get good responses from customers in Australia.” The main aim, according to Mauck, was to arm attendees with the knowledge needed to ask the right questions and cut through internal communication barriers and marketing fluff. “This is not a commercial for Hirschmann and Belden. It is about the technology and in fact we have attendees that use competitive products,” Mauck pointed out. “We want them to ask questions and

LEADERS: Belden’s Keith Mauck (L) and Chua Tek Guan. understand the technology and the importance of having infrastructures, products, projects, planning and design that fit the requirements of truly mission critical networks.” Chua Teck Guan, Belden’s director for South East Asia and North America, had also come to Australia for the event. According to Chua, the company was also looking for feedback from the customers on the ground, especially because of the specialist mining and oil and gas applications found in Australia Toward that end, a panel discussion was held on the third day, which featured Hirschmann and Belden product managers from Germany. “We wanted to get all the product managers out to the panel, with the customers giving us feedback on trends, and where they see technology going,”

Chua said. “The objective is to get feedback from the end market, and product managers from Germany will take that on and put it in a product roadmap, or enhance existing products to make them more suited for local applications.” Belden’s executives said that holding the seminar in Australia was an indication of the company’s support for the local market. In conversations with PACE, Mauck said the Australian industry would continue to grow for the company. “We want the market to know that Belden and Hirschmann are investing in the Australian market,” he said. “The customers here want to learn, and they appreciate good training and quality. This is a very unique market, and it’s an exciting place to be.” Each of the three days of the seminar continues on page 3 >

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NEWS

EDITOR’S MESSAGE

PACE

More growth ahead

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 Journalist: Isaac Leung Tel: (02) 9422 2956 Email: isaac.leung@reedbusiness.com.au Key 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 Co-ordinator: Jennifer Collinson Tel: (02) 9422 2657 Fax: (02) 9422 2722 Email: jennifer.collinson@reedbusiness.com.au

Next Issue • Sensors & Analysers • SCADA & MES • Process Control in Power Generation • Water & Wastewater

FOR many of us this is the time to ponder over what the next year will bring. After the presents have been packed away and the decorations pulled down, what can our industry look forward to in 2012? There are doomsayers who point to the adverse effects of the carbon tax, the mining tax and the political uncertainty. And then there is the reality. For all the negative talk, big business is investing heavily in resources. Just in the September 2011 quarter, the value of ‘investable’ projects – those under planning – increased to $894 billion, an increase of 7.5 per cent over the previous quarter. Even more heartening is the Deloitte Access Economics report which puts the value of ‘definite’ projects at $406.8 billion, a 51.3 per cent rise over the past year. The process control, instrumentation and automation industries will be beneficiaries. Reflecting the underlying confidence, investors aren’t holding back. Fourteen projects have tags of more than $10 billion; of these five have committed investments of over $30 billion.

The Deloitte Access Economics report expects growth to accelerate next year. This will cause even more strain on our limited pool of human resources. The government department handing out 457 visas should staff up sooner rather than later. Sadly, our education system simply cannot churn out engineers and technicians in adequate numbers. Much of the investment is focused on just three sectors – mining, energy and communications. On the plus side, this gives equipment and solutions vendors well defined targets to pursue but is very unbalanced from an overall economic point of view. Manufacturing is taking a beating and the food sector is not far behind. But a few neversay-die companies are drawing up plans to streamline their operations, boost efficiencies and stay profitable. Our industry certainly has a lot to offer in these areas. If you have developed an interesting application, do drop me an email. Readers of PACE relish going through case studies and we can never have enough of them in our magazine and on www.pacetoday.com.au. Kevin.Gomez@reedbusiness.com.au

TRAINING

continued from page 1

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commenced with a keynote session. The first day featured Yokogawa Electric’s Kazuhiko Takeoka and Makoto Suda who spoke about their company’s cyber security initiative for industrial control systems it provides to clients. The second day saw Luton Semple presenting on efforts to consolidate and upgrade Queensland Nickel’s process network. The third day featured Zoran Savic providing details on the new Hirschmann-certified training courses in Australia, to be offered by RMIT University, as announced in September. The sessions covered a variety of network-related topics, from choosing switches and cabling, to network management and design, to wireless and security. Attendees who chose to attend the five sessions related to network design progressed from fundamentals to advanced topics like redundancy, multicast traffic management and network traffic isolation. The practical lab sessions were popular, with many of the

Industrial networks are now squarely on the radar for hackers. sessions subscribed to capacity. The delegates at the seminar consisted of local distributors, trainers from RMIT who would be running the Hirschmann certified courses, as well as representatives from companies already using Hirschmann products, or in the process of upgrading to Hirschmann. Mark Sheather, systems integrator at MidCoast Water, said Hirschmann equipment is used throughout the utility’s treatment plants, but no one had the skill to configure the units. “I’m here to learn a bit more about them and what we can get out of them,” he told PACE. “The main expectation is to be able to sit down and configure some of the equipment once I get back. It looks like I will be able to do that fairly comfortably. The learning curve has been good.”

In discussions with Belden’s executives and at the sessions themselves, it became apparent that security, wireless and zero-second switchover redundancy are trends which are set to dominate the industrial network sector, but security was the dominating topic, following Yokogawa’s keynote. Addressing delegates during a session on network security, Belden’s product manager for network security, Mark Cooksley, said the publicity generated by the Stuxnet worm meant industrial networks are now a legitimate target and squarely on the radar for hackers. The product roadmap presented at the panel on the third day reflected Belden and Hirschmann’s response to the market trends, with new secure routers, network management software, wireless access points, embedded Ethernet switches, and rail switches, all set to be released late this year to early 2012. [PACE Senior Journalist Isaac Leung attended the Hirschmann 2011 Mission Critical Network Design Seminar.] www.belden.com www.hirschmann.com/en DECEMBER 2011 www.pacetoday.com.au 3

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NEWS

INNOVATION

Are we facing testing times? Not if you ask this exporter

ENTREPRENEUR: SensMar managing director Alan Neale.

TESTING: Chris Neale checks the retrofitting pneumatic level indicator. QUALITY: A batch of SensMar contents gauges undergoing temperature cycling. BY ISAAC LEUNG THE biggest problem for SensMar managing director Alan Neale is not a lack of business, or operational costs, but the uncertain foreign exchange rate. Considering the current state of the global economy, that is reasonable. But it is also an indication of just how successful the export strategy is for this local company. SensMar designs, manufactures, distributes measurement and control instrumentation products and systems, specialising in the process and marine industries. It is thriving on a brisk export business, reaping income in the form of Euros, US dollars and Pounds, while retaining product and skills development and manufacturing in Australia. “In our first 12 months of trading, 70 percent of output (all locally manufactured) was sold into the European, US and South East Asian Markets,” Neale told PACE. It’s certainly an unusual situation for a local company to be in, considering the heyday of manufacturing has long passed. 4 www.pacetoday.com.au DECEMBER 2011

“Some years ago, there were many manufacturers here in Australia,” Neale said. “If you look at the makeup of the industry in Australia today, it’s largely overseas owned or it’s salesmen who represent overseas products…we are just another outlet to the multinationals.” According to Neale, the secret behind SensMar’s success is its differentiation from larger manufacturers, with a highly organic and customer-centric approach to the manufacturing and design process, whether it pertains to the hardware or the accompanying software. “We talk to the customer, we can respond to their needs, we can tailormake the product to suit their application, and we can do these things on a short time scale,” Neale explained. “We always put great effort in being close to the customers in terms of understanding the product.” Neale, a consummate entrepreneur, has retained a well-developed customer base and connections from previous companies he managed. SensMar was founded to respond to demand from customers and suppliers. At first, it was run out of Neale’s garage,

but in June this year, it moved into a dedicated facility in Warriewood. There, Neale, his son Chris (who is the commercial director of the company) and two other employees draw and define the parts needed, and source them from local manufacturers. Of course, some electronics components are inevitably imported from factories in Asia or Europe. They are currently in the process of finalising an in-house calibration laboratory, which, after NATA accreditation, will be able to certify items and products to meet international standards for sale around the world. Neale is keen to emphasise that SensMar is still in its early days as a startup. “At this stage, it’s more pressing to get the production up to meet outstanding orders. We’ve got an order book that runs for more than 12 months now,” Neale said. The company is currently building more than fifty level measurement systems for a large European engineering group, and previously provided a number of flow devices for research projects at the University of Melbourne.

SALE: Single way sensor monitor.

Besides the marine and naval sectors, SensMar also has its eye on the water industry, where it expects growth due to the strength of that market in Australia. In the future, Neale hopes to find distributors to resell the company’s products in Australia, so SensMar can concentrate on its key operations of design, manufacture and testing. www.sensmar.com.au

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NEWS

EDUCATION

Training ushers women into resources industry

MOTIVATED: (l-r) Student Courtney Taylor; ACEPT director Greg Guppy; student Jessica Duchesne; Chevron student mentor Jenna Robertson.

EIGHTEEN women have been given a unique opportunity to gain careers in the resources and oil and gas sectors through new industry-sponsored scholarships at Challenger Institute of Technology. The Women in Engineering program is delivered in partnership with sponsor Chevron Australia. The students have received scholarships that enable them to study at Challenger’s oil and gas simulated plant facility, the Australian Centre for Energy and Process Training (ACEPT). A key focus of the course is to provide the women with an insight into engineering from a female perspective and to address barriers that might discourage women from entering an engineering career. On 28 September, the women were introduced to six mentors, women who have forged successful engineering careers with global energy company Chevron. In a unique initiative, the mentors will serve as role models to the women taking part in the course, contributing to lectures and a dedicated online forum in which students can raise questions. “We are thrilled to be able to offer additional support and guidance to the women by providing some of our female engineers to mentor and share their experiences and advice with those in the program,” Chevron Australia General

Manager Human Resources, Kaye Butler said. “The value a mentor provides to a mentee and to the wider organisation and community is widely acknowledged at Chevron. That is why we have a mentoring program available to all Chevron employees, and why we are very proud of our partnership with the Challenger Institute of Technology’s Women in Engineering Program.” This one-year Certificate III in Engineering has been specifically designed to provide women candidates with skills and employment prospects through a supportive learning program that includes visits to Chevron Australia’s engineering and design offices. “To have 18 women in this group is great progress, for as recently as three years ago the roles for women at this facility would have been very limited in both number and the scope of duties – most likely they would have only been seen behind the reception,” said Challenger chief executive officer, Liz Harris. “These women are now looking at a very positive future in the resources industry and are forging a path for women in the industry.” “Chevron’s support is a great reflection of how successful training can be when we work closely with our industry partners,” Harris added. www.acept.challenger.wa.edu.au DECEMBER 2011 www.pacetoday.com.au 5

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OPINION

MANUFACTURING

Advanced automation Manufacturing can take advantage of the benefits of integrated architecture, writes David Black.

NTEGRATED Architecture facilitates the convergence of control and automation processes to streamline production and information management across an entire manufacturing or processing plant. Taking the approach that integrated architecture can be scalable helps ensure that manufacturing enterprises, large or mid-range can take advantage of the benefits. The provision of integrated architecture is becoming widely accepted by many automation and control providers for use by OEMs and machine builders. Designed to provide a full range of automation disciplines â&#x20AC;&#x201C; including motion, process and drive control, safety and data/information transference; integrated architecture offers a means of reducing total cost of ownership for the overall system. There is a perception however that it is more applicable to larger sites, where there may be thousands of I/Os, controllers, switches and drives, with an enormous amount of data and information management. The use of integrated architecture for production management was often deemed to be more appropriate for larger organisations. Not so. Planning and the right approach to integrated architecture will work equally well on mid-range applications. In fact, it is possible to scale integrated architecture to suit virtually any size operation. Historically manufacturers may have utilised a different set of system tools for their large and small control systems, comprising different software configuration utilities and programming techniques. The Rockwell Automation Integrated Architecture system offers scalable, integrated safety, motion control, and visualisation capabilities that are suitable for machine builders and end users who want a single control and development environment, regardless of application size, discipline or complexity. The use of a single control infrastructure enables designers to create re-usable code and practices across their product offerings, thereby reducing 6 www.pacetoday.com.au DECEMBER 2011

SCALABLE: The key to integrated architecture lies in its scalability across multiple controllers and graphic interfaces utilising a common set of programming and configuration tools.

Historically manufacturers may have utilised a different set of system tools for their large and small control systems comprising different software configuration utilities and programming techniques. development time and costs. Integrated architecture is further streamlined with the advent of network protocols such as Ethernet/IP. Not only can all devices talk to each other, but distribution across a common network with standard enterprise applications can be accommodated. The IT department

is now in a position to help the engineer on the factory floor to manage the entire network, facilitate remote operation, increase network security and help ensure all safety measures are in place. The flow-on effect is a reduction in maintenance costs and a greater ability to incorporate additional devices and cross-communication with other business applications. The key benefit of integrated architecture lies in its scalability across multiple controllers and graphic interfaces utilising a common set of programming and configuration tools. The advantage in the method of programming is by developing blocks of code, the OEMs and machine builders can replicate basic functions throughout their solution set, minimising the development time for each new project. Whilst the physical modules may appear slightly different between large and mid-

range applications, the programming languages are the same. Utilising a network protocol such as Ethernet/IP for the system backbone simplifies the process of adding supplementary controllers and enhances the ability to â&#x20AC;&#x2DC;scale upâ&#x20AC;&#x2122; the architecture in a trouble-free manner. Installing additional packaging processes, ingredients, tools or an entire new production line is achievable. Modifications can be achieved without affecting or interrupting the process of operation. There is no compromise on controller functionality in scalable integrated architecture. What is available for a large-scale application is deliverable to a mid-range version. The standard suite of controllers, I/O, visualisation, motion, drives, safety, asset management and information are all included. It goes without saying, that the size of the application will determine the number of ports required on the switch;

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the number of I/Os to cater for; the number of viewing terminals and how safety and asset management is to be integrated. It is up to the OEM or machine builder to help the end-user determine which size component is appropriate for their application(s) and how it should be configured across the network. The days of hard-wired safety on the manufacturing line are dwindling. Safety products utilised within an integrated architecture structure use common programming and network environments to provide full functionality. Integrated Architecture utilises common programming and network environments to support safety solutions within a scalable environment. Most integrated architecture solutions will incorporate the necessary tools to control assets, maintenance schedules and servicing which are appropriate to the size of the application. Visualisation packages supporting asset management will help ensure that data and information is displayed in real-time and has the ability to communicate changes in batch processing, maintenance schedules and system monitoring. This may be further facilitated by offering a common network such as Ethernet/IP, which allows for a more seamless flow of information. Ethernet/IP is gaining ground, based on common use at the enterprise level. Most users are familiar with navigating web browsers, document generation and

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The flow-on effect is a reduction in maintenance costs and a greater ability to incorporate additional devices and crosscommunication with other business applications.

file location. Many of these user interfaces are now replicated in the factory floor, creating a more streamlined environment for application usage and training, for both the IT department and staff. Implementing the systems required for the factory floor and enterprise, over the same network protocol maintains the functionality of applications such as drives or motion controllers. The introduction of virtual LANs for dedicated applications such as CCTV, graphic interfaces or specific processes reduces the required bandwidth over the network, minimising ‘slowdown’ experienced by production or the enterprise. Equally, should one virtual LAN ‘crash’, it does not incapacitate the entire plant. Security is often a concern with Ethernet/IP protocols as it has the potential for viruses and malware, to

progress further through the company. This is readily rectified with secure switches, firewalls and access controls – all of which are required to maintain security for a business, large or midrange. Collaborations between companies also provide solutions and products designed to provide secure access for integrated architecture environments. OEMs and machine builders need to be fully conversant with the philosophy and implementation of integrated architecture. As differing companies supply their own versions of system integration to OEMs and machine builders, the products offered to the end-user need to be compatible, or available in a variety of formats. It is becoming rare to employ a converter to facilitate communication between two devices from separate suppliers. The advantage to OEMs and machine builders utilising integrated architecture is the reduced development time and familiarity with programming formats. By developing a set of ‘cookiecut’ applications for each type of machine, they can be applied across many systems, saving the end-user time and money in the design and development cycle. As a conduit to the automation and control supplier, the OEM and machine builder is responsible for the implementation of the latest in software updates and features for their customers’ systems.

While many OEMs and machine builders will write their own routines based on the suppliers’ code, it is important to install the current versions to take advantage of the latest features available; using a new controller with an old version of device software will still run, but visibility of the feature is not assured. Automation and control companies provide the opportunity for registered users to download software updates via the internet as and when they are released. Essentially, scalability takes the applications used in a large scale enterprise and adapts them to smaller midrange systems. With a common set of resources and tools to handle safety, motion, control, information and visualisation, it is an ideal way for machine builders and OEMs to develop a suite of solutions in a timely, cost effective manner. With pre-planning and advice, an application can be catered for. The key will be to talk to an OEM or machine builder to select the appropriate components and programming technique to maximise the features and cost savings, regardless of whether it is a large, small or mid-range system. [David Black is Product Manager, Architecture & Software, South Pacific Region for Rockwell Automation.] Rockwell Automation www.rockwellautomation.com.au

DECEMBER 2011 www.pacetoday.com.au 7

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OPINION

HUMAN MACHINE INTERFACE

HMI platforms are evolving The HMI device can help solve manufacturing problems, writes Craig Resnick.

HE worldwide human machine interface (HMI) platform market continues to evolve to meet the needs of both discrete and process manufacturers and the OEMs that serve these markets. Rather than being just a standalone component, the HMI device is evolving into a platform that helps solve manufacturing problems to improve business performance. Furthermore, users are turning to open systems and commercial-offthe-shelf technologies to meet their increasing demands for high performance, ease of use, and lower total cost of ownership. Although technological advancement will continue to be an important factor, the focus of manufacturers, processors, and OEMs has moved toward seeking solutions that help them manage their manufacturing operations, while dealing with the reality of having to pare back their in-house engineering and automation system support capabilities. In addition, global competitive pressures require users to increase integration of automation with other enterprise applications. Suppliers have responded to these requirements by providing HMI platforms that use object-based technologies and provide Internet access to move their solutions from standalone, application-specific platforms to become a key component of an automation solutions portfolio. Increasingly, HMI platforms help users visualise key metrics and KPIs, such as overall equipment effectiveness (OEE) and energy savings, to help them quantify the benefits of their automation investments. These users are all too aware of global competition and escalating energy costs, as well as the need for automation equipment that can help them achieve more flexible production, while reducing environmental impacts. However, users must go through a business justification process before they can replace their existing, less-efficient equipment. This business justification requires clear metrics regarding the

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return on investment (ROI) and return on assets (ROA) of each purchase. Increasingly, they use their new HMI platforms as the digital dashboard to visualise and quantify these metrics. Today, HMI platforms – in conjunction with programmable logic controllers (PLCs) or more highly functional programmable automation controllers (PACs) – have become a primary building block for industrial automation systems in many manufacturing plants. Increasingly, however, users want the HMI platform to serve not only as an operator inter-face window into the application, but as an enterprise integration tool. As the trend toward open systems in the automation and enterprise markets continues to unfold, the HMI platform emerges as a single device to support a wide range of applications. At the low end of the market (characterised by small, fully integrated, lowcost products), HMI platforms can form the basis of an embedded control product for a wide range of OEM product applications. At the high end of the market (characterised by manufacturing processes integrated to global operations), HMI platforms provide data and information visibility across the plant floor and throughout the enterprise. Over the past 15 years, HMI platforms have displaced conventional operator input devices and display elements – such as hardwired push buttons, lights, and LED numerical displays – providing substantial savings in wiring and space. The tremendous cost efficiency of graphical display devices and commercial software technology has largely displaced hardwired panels and pushbuttons. The simplicity of the design and the flexibility afforded by the easily modified software programs also drive the market toward scalable HMI plat-forms in lieu of panels and pushbuttons. With continuously shrinking component costs and improved designs, processors, and soft-ware-based systems,

HMI platforms in conjunction with PLCs or more highly functional PACs have now become a primary building block for industrial automation systems in many manufacturing plants.

today's HMI platforms offer compact configurations, flexible handling, rich features, and competitive pricing. They can also offer increased reliability, with mean times between failures (MTBF) for hardware components typically measured in years of continuous operation. Hardware reliability is achieved by minimising physical faults by eliminating failure-prone components and performing extensive burn-in testing, so reliability should not become an issue until well along in the platform's service life. Software reliability, however, is not measured as a direct function of time. It is achieved by eliminating design faults and performing extensive functionality testing and debugging. Unlike hardware, software reliability does not diminish over time. However, software reliability can be affected each time an upgrade is made. This has been an argument that bodes well for the HMI platform, as the embedded software has been included as part of the extensive functionality and burn-in testing is performed prior to delivery to the user. As a result, the HMI platform is not subject to continuous software upgrades that could negatively impact reliability. End user companies are increasing their agility by accessing and visualising real-time information and applying it to speed up and improve operations; inte-

grating business, manufacturing, and production within the operations management realm. These users are deploying operations management solutions based on industry standards to standardise visualisation and IT infrastructure across multiple facilities. This standardisation of visualisation is a driving force in the growth of HMI platforms. These users seek to reduce IT and engineering costs by implementing rapidly deployable and easy-to-manage visualisation applications. They want to take the pain out of expanding and managing disparate systems by transforming their HMI platforms into enterprise-wide collaboration tools, without disrupting their current operations. A key reason that HMI platforms are growing in popularity is their ability to lower maintenance time and expense for OEMs and end users. HMI platforms that support automation and enterprise applications can provide the control room operators and maintenance technicians with information to speed up maintenance operations and reduce interruptions. These HMI platforms provide maintenance crews with access to the company's maintenance management system at either the control room level or directly at the machine, equipment, or unit level. Some HMI platforms are configured to incorporate HMI, configuration procedures, programming languages, and maintenance procedures. This provides a common interface, and allows the user to achieve the operational benefits of transparent integration between each domain. ARC’s upcoming latest worldwide HMI Software study, along with ARC’s worldwide Operator Interface Terminal study, addresses in depth many of the issues and trends relating to HMI platforms. [Craig Resnick (CResnick@ arcweb.com) is Research Director, ARC Advisory Group.] www.ARCweb.com

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IN FOCUS

Advanced pressure diagnostics Advanced diagnostics embedded in a pressure transmitter can detect integrity issues in the electrical loop between the transmitter and the host system, write Erik Mathiason, Jessica Lo and Natalie Strehlke.

RESSURE transmitters measure pressure, flow, or level and may be used to control or monitor changes in a process. To receive these measurements, an operator relies on successful communication between the transmitter and the host system. A pressure transmitter with advanced diagnostics technology can detect issues with the integrity of this connection and proactively alert the operator of the possibility of miscommunication. This technology can also provide a means for early detection of abnormal situations in a process environment (as described in the article in the PACE August 2011 issue page 20 titled “How

to enhance your process insight”). Having comprehensive diagnostic coverage improves the transmitter’s overall safety levels to the highest levels seen in the industry. Advanced diagnostics technology enables the user to respond to changes in both the process and electrical loop, troubleshoot, and proactively prevent future shutdowns.

Electrical loop integrity

FIGURE 1: Power advisory diagnostic technology.

Most pressure transmitters communicate using the 4-20 mA analogue signal. To allow more information to be introduced into traditional automation networks, the HART protocol was created as a standard for sending and > receiving digital information via

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IN FOCUS

Advanced diagnostics technology enables the user to proactively respond to changes in both the process and electrical loop and prevent future shutdowns.

existing analogue wiring. HART technology has been used to introduce many new transmitter innovations by utilising this digital signal. In order to accurately obtain all of the information that is being communicated by the transmitter, an operator relies on the integrity of the electrical loop. Advanced diagnostics embedded in the pressure transmitter provide detection capabilities for failure modes that could occur in the electrical loop, such as power supply failures and on-scale measurement failures. Power advisory diagnostics monitor transmitter terminal voltage and sends notifications of unwanted changes on the electrical loop. Characterisation of the electrical loop is completed when the diagnostic is enabled. The transmitter then automatically drives the terminal voltage to its low (20 mA) voltage and high (4 mA) voltage outputs. The characterisation constructs a linear line between the two points (similar to Figure 1), and sets high and low voltage deviation limits that are parallel to that line. When a deviation outside the limit occurs, a HART alert or analogue alarm will be sent to the host system. Many abnormal events can compromise the integrity of an electrical loop. From rainstorms to faulty power 10 www.pacetoday.com.au DECEMBER 2011

supplies to corroded terminals, each one of these events can cause the control system to receive an incorrect 4-20 mA signal from the transmitter. An issue that can occur is condensation accumulating in the terminal compartment, a result of poor conduit sealing. With enough water in the compartment a short may occur, causing an incorrect output signal (see example in Figure 2).

Spike in output Another issue that power advisory diagnostics can detect is an unstable power supply. Power supplies that drift or spike in output often indicate that the power supply is faulty and unreliable. Also, if the supply voltage decreases the transmitter may not have enough power to reach a high alarm value. Power advisory diagnostics calculates the power supply input and compares it against the characterisation that was recorded during setup. This ensures that the varying power supply is not compromising the electrical loop. Advanced diagnostics can detect certain types of on-scale failures by monitoring the transmitter power consumption and the 4-20 mA output. Monitoring the transmitter power consumption is critical to ensure that it can drive the appropriate alarm action

SNAPSHOT

on-scale failure or even a loss of HART communication.

TECH SPECS The Rosemount 3051S Pressure Transmitter with advanced diagnostics technology claims to have the industry’s highest diagnostic coverage with a Safe Failure Fraction of 96.7 percent and the lowest dangerous undetected failures, resulting in the lowest PFD transmitter on the market. To achieve this rating, a number of internal transmitter focused diagnostics were added, such as power consumption and mA output. This transmitter can detect external failures that occur in the electrical loop and process that may otherwise go undetected. Electrical loop diagnostics is where the transmitter learns the voltage characteristics of the loop and alerts the operator if something changes.

when required. The transmitter should not consume more than 3.6 mA of current so it can drive to low alarm. Additional diagnostics verify that the analogue 4-20 mA loop accurately reflects the pressure value. The conditions described above could result in an analogue

Safety coverage One measure of safety coverage, as defined per IEC 61511 “Functional Safety: Safety Instrumented Systems for the Process Industry Sector,” is the Probability of Failure on Demand or PFD. PFD is defined as the probability that the SIS loop or device (transmitter) will have a failure or be in a failure mode upon demand when needed during a hazardous situation. This is undesirable as it impacts the ability for the SIS loop to function properly and prevent a catastrophic event from occurring. The Probability of Failure on Demand of a transmitter is heavily influenced by the transmitter’s dangerous undetected failures. Dangerous undetected failures are identified during a Failure Modes, Effects and Diagnostics Analysis (FMEDA), conducted by a third party. During this activity the circuitry is analysed component by component and each assigned failure modes. Each failure mode is classified as safe detected, safe undetected, dangerous detected and dangerous undetected and then assigned a probability. The numbers are based on the type of component and a large data-

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base of historical failure rates. Dangerous undetected failures are the most concerning as they may result in the transmitter not being able to perform properly during a safety shutdown event. A typical example of a failure that can occur within an electrical loop is a brown out. This is where there is enough power for the transmitter to operate but not enough power for the transmitter to reach 20 mA or to go to high alarm.

Process noise Process diagnostics is where the transmitter uses statistical process monitoring to look at process noise and detect an abnormal process condition. The transmitter first generates a process noise baseline and will tell you if it has changed outside the limits you configure. A typical example of a failure in this area is plugged impulse lines (see Figure 3). Many other failures can be detected as well including loss of agitation, change in aeration or solids, and pump cavitations. When you factor in the internally

FIGURE 2: The schematic above illustrates examples of electrical loop issues detectable by power advisory diagnostics.

focused diagnostics, as well as electrical loop and process diagnostics, you can achieve the safest, most reliable transmitter for use in an SIS system. In conclusion, advanced diagnostics can provide a means to ensure the operator is receiving the correct data values from the transmitter. This comprehensive detection coverage increases the pressure transmitterâ&#x20AC;&#x2122;s overall safety levels to the highest in the industry. Advanced diagnostics technology enables the user to proactively respond to changes in both the process and electrical loop, troubleshoot, and prevent future shutdowns. [Erik Mathiason is Marketing Engineer, Pressure Diagnostics; Jessica Lo is Senior Engineer, Pressure Research and Development; Natalie Strehlke is Product Marketing Manager, Pressure Technology. All three are with Emerson Process Management.] Emerson Process Management 03 9721 0200 Rosemount.com/3051SDiagnostics

FIGURE 3: Comprehensive protection from the process to the host.

Meet all your needs with one cost-effective controller. When you need a flexible, scaleable, integrated control and motion solution, Logix is the answer. From simple to complex machinery CompactLogixâ&#x201E;˘ is Integrated Architecture in its simplest form helping reduce the volume of hardware Experience your future today, visit: www.RockwellAutomation.com/ think/yourfuture

you need, making it quicker for you to meet your customersâ&#x20AC;&#x2122; requirements. www.RockwellAutomation.com.au www.RockwellAutomation.co.nz

DECEMBER 2011 www.pacetoday.com.au 11

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Controlling real-time efficiency Choosing the right process technology can help food and beverage manufacturers reduce on-shelf product errors and achieve real-time efficiency, writes Annie Dang.

INSPECTION: Checking for cracks and other flaws in bottle necks and rims. This inspection also looks for foreign matter, such as glue or cardboard, which shouldn’t be there. The production line is running at 16 bottles per second.

ECHNOLOGY designed to better control the end-of-theline manufacturing processes, including coding and packaging, can provide food and beverage manufacturers with a cost-efficient solution that not only reduces production costs but also product liability. "In food manufacturing, coding and labelling errors could cost manufacturers dearly because they often require reworking," Matthews' manger for identification systems, Mark Dingley, told PACE. "Reworking could involve going back and repackaging the defective production or completely reproducing that product. Either way, both processes would require extra time spent by workers to fix the defect and also extra material to reproduce that product."

12 www.pacetoday.com.au DECEMBER 2011

However, eliminating coding and labelling errors is about more than just production efficiency and waste management; it is about cost management. "Manufacturers are now checking for coding and barcoding errors all the way along the production process, from primary through to cartoning or palletisation," Dingley explains. "The idea is to control wastage costs by checking the product in stages as it comes down the line, rather than checking all at once as it comes off the production line. This allows manufacturers to correct an error without stopping an entire plant's production, and reduces potential costs which could arise as a result of coding or packaging error." One technology helping local food and beverage manufacturers better monitor and control the production

quality to eliminate product recall, rework, lost production and material wastage is iDSnet – a package code management system designed to deliver a true product-traceability solution throughout manufacturing businesses, thus streamlining operations. Using iDSnet technology, in addition to eliminating coding and labelling errors, manufacturers can better control the production process by assessing performance speeds, optimal efficiency and overall efficiency to see if they are meeting their efficiency targets, says Dingley. "The technology captures information from various points along the production line – such as scanners, photo eyes, vision inspection systems, packaging equipment and so on – showing the true performance of those production lines in real time.

The idea is to control wastage costs by checking the product in stages as it comes down the line, rather than checking all at once as it comes off the production line. Manufacturers can look at the data to see how effective their production line is, to determine how to achieve overall equipment effective (OEE) standards," he says. "Having access to real-time data gives manufacturers the ability to make

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Innovative valve automation

TESTING: An iQVision screen shot showing a bottle rim and neck inspection. The green line shows the check to make sure there are no defects or flaws and no foreign matter. This product passes.

Measure your process & do something about it With modern technology valves are transformed. Seamlessly integrated positioners, feedbacks, pilots, network interfaces or integrated PID process controllers have opened limitless possibilities in process control.

We make ideas flow WATCHFUL: iQVision managing director Ken Razga overseeing an inspection checking for cracks and other flaws in bottle necks and rims. This inspection also looks for foreign matter, such as glue or cardboard, which should not be there.

www.burkert.com.au | 1300 888 868

DECEMBER 2011 www.pacetoday.com.au 13

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decisions based on how their production line is running in actual time or over a certain period of time, and informs them of any issues, such as stoppages, as they may arise down the production line." Omron Electronics product specialist for machine vision, Panfilo Tarulli, says checking for product defects as goods come down the line is definitely the more cost-efficient method, rather than waiting to check the completed products at the end. "Most food lines operate at very high speeds. Within an hour, if a defect is not recognised, the manufacturers can lose thousands of defective products. At this stage, the product can be reworked, but at a heavy cost to the manufacturer," Tarulli told PACE. "But once labels are applied to the defective product, the cost of reworking becomes too expensive. The manufacturer is better off disposing of the defective product and reproducing a new batch. Reproduction however does come at a cost: a new roster for the reproduc14 www.pacetoday.com.au DECEMBER 2011

Knowing how to read and interpret such data not only helps to build worker confidence it empowers them to take greater control over their work. tion needs to be scheduled and more raw materials need to be used, which adds to the cost of production." A technology that is helping food and beverage manufactures better manage their production costs and reduce labelling errors is machine vision â&#x20AC;&#x201C; an imaging-based technology that provides continuous inspection of products on a production line. "You can install a vision system after each process or after several processes â&#x20AC;&#x201C; it really depends on where the waste is having the biggest impact on your yield

rates," says Tarulli. "If for example you lose in a year $70,000 dollars in defective products, then a $40,000 vision system fully installed and commissioned has just saved you $30,000 in your first year alone."

Human intervention Tarulli says Omron's FZ3 vision system sets a reference point, which is used to compare products on your line. The measurements received fill levels, expiry dates, codes and label information are analysed, and adjustments can be made to set your optimum efficiency level. Vision systems are also used in areas where human intervention creates problems. The idea is not to replace workers in the production process, but to maximise their skills in other areas of production. This could mean workers spend their time monitoring the line and ensuring that all processes and systems are in place and functioning, rather than checking products.

Though such technology provides opportunities for manufacturers to achieve higher returns in the food and beverage industry, for workers on the factory floor it provides a source for acquiring new skills. "Workers on the floor can monitor and access the data through these systems, via scoreboards, which inform them in real-time of how the line is running, whether there are any errors and how efficiently it is running," says Dingley from Matthews. "Knowing how to read and interpret such data not only helps to build worker confidence, it empowers them to take greater control over their work. Overall, it lifts their skills level and improves efficiency." Omron Electronics 1300 766 766 www.omron.com.au Matthews 1800 333 074 www.matthews.com.au

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Water and energy gains for brewer Hunter Valley based brewery reduces its demands on fossil fuels and electricity for wastewater treatment by using energy-friendly anaerobic pre-treatment technology. AEROBIC TANKS: Many of the latest installations use advanced technologies such as aerobic polishing to enhance water discharge purities.

WATER recovery plant designed to target world’s best-practice water reuse standards in the food and beverage industry has exceeded its designers’ expectations in its first year of service at a brewery in Australia. The waste water treatment and green energy plant at the $120 million Pacific Beverages’ Bluetongue Brewery in NSW also provides renewable energy for the brewery, reducing its dependence on fossil fuels and ultimately cutting overall energy needs by 15 per cent.

Performance targets The plant – engineered by Australia’s CST Wastewater Solutions in partner-

The plant’s design philosophy has been to treat the waste water as a resource from which water and energy can be recovered in addition to reducing the site’s carbon foot print. ship with Global Water Engineering – has achieved all the environmental performance targets set by Pacific

Beverages, a SABMiller/ Coca Cola Amatil joint venture, according to CST Wastewater Solutions Managing Director Mike Bambridge. The plant was also a finalist in two categories of this year’s Engineering Excellence Awards, Sydney 2011, conducted by Engineers Australia, which attracted a record field of more than 90 entrants.

Award winner Bluetongue was a finalist in the Environmental and Heritage category and the Products, Manufacturing, Facilities and Processes category. Pacific Beverages designed the plant to ultimately have an annual capacity of

150 million litres, while targeting a reduction in water usage to 2.2 litres per litre of beer produced. This figure is amongst the best in the world and certainly well above the global average of four to five litres of water to every one litre of beer, says the CEO of Pacific Beverages, Peter McLoughlin.

Green energy The GWE anaerobic technology plant employed at the plant produces sufficient green energy (methane) from its closed anaerobic reactor to power a designated steam boiler and cut the brewery’s overall energy consumption by about 15 per cent. This equates to > about 300,000 Mj. DECEMBER 2011 www.pacetoday.com.au 15

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CONSERVATION: Bluetongue Brewery uses 2.2 litres of water for each litre of beer produced.

Many of the latest installations use advanced technologies to enhance water discharge purities while converting waste to methane to be burned to power boiler and hot water systems.

Bambridge says the plant indirectly reduces the brewery’s carbon footprint by reducing the brewery’s demands on fossil fuels and the electricity needs for wastewater treatment by using energyfriendly anaerobic pre-treatment technology in which GWE is considered a world leader.

Fresh water “And the plant produces treated effluent to be safely reused as process and cleaning water within the brewery, reducing by approximately 50 per cent 16 www.pacetoday.com.au DECEMBER 2011

the need for fresh water, thereby greatly contributing to reducing the amount of water typically used to produce a litre of beer,” says Bambridge. The design philosophy has been to treat the waste water as a resource from which water and energy can be recovered in addition to reducing the site’s carbon foot print. “This is a landmark achievement of water conservation and green energy production, achieved by combining the latest versions of advanced and reliable technologies available globally,” says Bambridge. “It demonstrates the technology’s practicality for extensive use not only throughout the Australian food and beverage sector – which involves more than 20,000 companies – but also globally, notes Bambridge.

Industrial effluent His company employed the latest technologies from a range proven globally by Global Water Engineering (GWE), headed by CEO Jean Pierre Ombregt. GWE has built more than 250 plants producing biogas as part of the indus-

MONITORING: Bluetongue plant operator Matt Edmundson keeps a close watch on the processes from the control room.

trial effluent clean-up system, of which more than 75 were supplied with subsequent biogas utilisation systems for clients worldwide.

Global players Users of GWE technologies extend from the Bluetongue Brewery to global players such as Budweiser, Chang, Carlsberg,

Coca Cola, Corn Products, Danone, Fosters, Heineken, Interbrew, Kraft, National Starch & Chemicals, Nestlé, Pepsi Cola, SAB-Miller, San Miguel, Singha, Sunkist and Tsingtao. Many of the latest installations use advanced technologies – including anaerobic pre-treatment of water and aerobic polishing – to enhance water

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SNAPSHOT

BENEFITS Highlights of the system’s performance in its first year of service include: ❏ The COD removal rates over the anaerobic reactor have consistently been above the design of 85 per cent removal. The same for the biogas production which has been better than theoretical production rates approximately1,436 Nm3/d at 80 per cent CH4 at average loading (approximately 2,157 Nm3/d at maximum loading). ❏ The performance of the wastewater plant has enabled Pacific Beverages to be on target to meet its goal to be world’s best practice for breweries in water management by using only 2.2 litres of water for each litre of beer produced. ❏ This WWTP has leading edge wastewater technologies including anaerobic pre-treatment, MBR (Membrane bioreactor) and RO (reverse osmosis) as well biogas reuse.

discharge purities while converting waste to methane to be burned to power boiler and hot water systems, for example, or to power generators and permanently replace fossil fuels. On average, the removal efficiency of GWE’s anaerobic wastewater treatment installations is 90 to 95 per cent, bringing the organic load down to regulatory discharge standards for most types of wastewater, says Ombregt.

Environmental advantage Besides the economic advantages of anaerobic wastewater treatment, there is also a clear environmental advantage in significantly reducing a factory’s carbon footprint. This is done not only by supplying renewable energy from the closed anaerobic reactor, thus reducing or even eliminating reliance on fossil fuels, but also by replacing traditional, open, methaneproducing lagoons, and by replacing power-consuming, sludge-producing aerobic WWTPs. “The concept of using wastewater to create green energy is much more widely applicable than often realised. Any factory with a biological waste

COMPACT: Total treatment installation with anaerobic reactor and balance tank on the left and aerobic tanks on the right.

stream or wastewater with high COD (chemical oxygen demand) can easily use this model to generate energy,” says Ombregt.

Anaerobic basics In the absence of oxygen, many different groups of anaerobic bacteria "work" together to degrade complex organic pollutants in methane and carbon dioxide. The microbiology is more complex and delicate than in case of aerobic processes, were most bacteria are able to "work" individually. As a result anaerobic systems require more control and monitoring systems to operate successfully. Each system has its advantages and disadvantages, but for treatment of industrial wastewaters, the advantages of anaerobic systems are most often predominant. Global Water Engineering mail@globalwe.com www.globalwaterengineering.com CST Wastewater Solutions 02 9417 3611 www.cstwastewater.com

SUSTAINABLE: The anaerobic reactor used to produce green energy. DECEMBER 2011 www.pacetoday.com.au 17

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IN FOCUS

Calibrating temperature instruments While standards determine accuracy to which manufacturers must comply they nevertheless do not determine the permanency of accuracy.

HE most commonly and most frequently measurable variable in industry is temperature. Temperature greatly influences many physical features of matter, and its influence on quality, energy consumption and environmental emission is significant. Temperature, being a state of equilibrium, makes it different from other quantities. A temperature measurement consists of several time constants and it is crucial to wait until thermal equilibrium is reached before measuring. Metrology contains mathematic formulas for calculating uncertainty. The polynoms are specified in ITS 90 table (International Temperature Scale of 1990). For each measurement, a model that includes all influencing factors must be created.

longer distance than the plant. Therefore, temperature transmitters were developed to convert the sensor signal into a format that can be transmitted easier. Most commonly, the transmitter converts the signal from the temperature sensor into a standard ranging between 4 and 20 mA. Nowadays, transmitters with a digital output signal, such as Fieldbus transmitters, are also being adopted, while the transmitter converts the sensor signal, it also has an impact on the total accuracy, and therefore the transmitter must be calibrated on regular basis. A temperature transmitter can be calibrated using a temperature calibrator.

Calibrating instruments

Determine accuracy Every temperature measurement is different, which makes the temperature calibration process slow and expensive. While standards determine accuracy to which manufacturers must comply, they nevertheless do not determine the permanency of accuracy. Therefore, the user must be sure to verify the permanency of accuracy. If temperature is a significant measurable variable from the point of view of the process, it is necessary to calibrate the instrument and the temperature sensor. It is important to keep in mind an old saying: all meters, including sensors, show incorrectly, calibration will prove by how much.

ACCURACY: All meters show incorrectly. Calibration will prove by how much.

Many factors influence the total uncertainty and performing calibration is not the least influencing factor.

Temperature sensors The most commonly used sensors in the industry used for measuring temperature are temperature sensors. They either convert temperature into resistance (Resistance Temperature Detectors, RTD) or convert temperature into low voltage (Thermocouples, T/C). RTDs are based on the fact 18 www.pacetoday.com.au DECEMBER 2011

that the resistance changes with temperature. Pt100 is a common RTD type made of platinum and its resistance in 0Â°C is 100 ohms. Thermocouple consists of two different metal wires connected together. If the connections (hot junction and cold junction) are at different

temperatures, a small temperature dependent voltage difference/ current can be detected. This means that the thermocouple is not measuring the temperature, but the difference in temperature. The most common T/C type is the K-type (NiCr/NiAl). Despite their lower sensitivity (low Seebeck coefficient), the noble thermo-elements S-, R- or B-type (PtRh/Pt, PtRh/Pt/Rh) are used especially in high temperatures for better accuracy and stability.

Temperature transmitters The signal from the temperature sensor cannot be transmitted a

To calibrate a temperature sensor, it must be inserted into a known temperature. Sensors are calibrated either by using temperature dry blocks for industrial field or liquid baths (laboratory). To make comparisons, we compare the sensor to be calibrated and the reference sensor. The most important criterion in the calibration of temperature sensors is how accurate the sensors are at the same temperature. The heat source may also have an internal temperature measurement that can be used as reference, but to achieve better accuracy and reliability, an external reference temperature sensor is recommended. The uncertainty of calibration is not the same as the accuracy of the device. Many factors influence the total uncertainty, and performing calibration is not the least influencing factor. All heat sources show measurement errors due to their mechanical design and thermodynamic properties.

Measurement uncertainty These effects can be quantified to determine the heat sourceâ&#x20AC;&#x2122;s contribution to the measurement uncertainty. The major sources of measurement uncertainty are axial homogeneity, radial

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homogeneity, loading effect, stability and immersion depth. Guidelines for minimising measurement uncertainty should be applied according to Euramet/cg-13/v.01 (former EA-10/13). The key parameters to understand are as follows: ❏ Axial homogeneity which is the temperature distribution in the measurement zone along the boring (axial temperature distribution). ❏ Radial homogeneity can be explained as the difference in temperature occurring between the borings. ❏ When several sensors are placed in the borings of the heat source, they will affect accuracy. This phenomenon is called loading effect. ❏ Stability means variation of the temperature in the measurement zone over time when the system has reached equilibrium. Thirty minutes is commonly used. ❏ To achieve a more stable calibration, the immersion depth for a probe should be sufficient for the sensor

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being calibrated. Stem conduction, heat flux along the length of the thermometer stem, affects both the reference sensor and the unit being tested.

Accuracy requirements

INTEGRATED: The Field Temperature and Metrology Temperature Blocks from Beamex.

The calibration of instruments and sensors must be performed periodically. The ISO Quality Control System presupposes the quality control of calibration, the calibration of instruments effecting production, regular calibration of sensors and traceable calibration as well as calibration documentation. The level of performance a calibration device needs to have depends on the accuracy requirements determined by each company. However, the calibration device must always be more accurate than the instrument or sensor being calibrated. Calibration of instruments and sensors can be carried out either on site or in a laboratory. AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au

DECEMBER 2011 www.pacetoday.com.au 19

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Motors driven by innovation Innovative developments in motors and drives are set to deliver significant productivity gains as well as environmental benefits, writes Hartley Henderson.

‘E

NERGY efficiency’ is the phrase of the hour for manufacturing operations, and so too for developers of industrial motors and drives technology. ABB Australia senior vice president, discrete automation and motion, Jussi Rautee, told PACE that because motors are the biggest energy users in industrial plants, the company has a strong focus on energy efficiency. It also focuses heavily on power output, in the design of its motors and drives. “For example, we recently launched a trailblazing high output synchronous reluctance motor and drive package with a power density up to 40 percent higher than a conventional induction motor,” he says. “Power density is coupled with high efficiency, resulting in high output, a compact design and low energy consumption.” The new motor, which combines innovative rotor technology and conventional stator technology, is designed without rotor windings, which means rotor loss is practically eliminated. Up to 40 percent higher output at 3,000 rpm is generated compared to conventional motors. “This powerful yet compact motor and drive package is up to two frame sizes smaller than a corresponding induction motor, and is suitable for a wide range of industrial applications, including with compressors, pumps and fans,” explains Rautee.

WASHDOWN: Two-stage helical bevel gear unit from NORD Drivesystems AU.

EFFICIENCY: WEG Australia’s latest motors reduce energy loss.

The new motor combines innovative rotor technology and conventional stator technology and is designed without rotor windings which means rotor loss is practically eliminated.

The company recently-released a Smart Servo Package (SSP) aimed at making a servomotor drive automation task simpler and faster to implement. The SSP is comprised of programmable or purely configurable SEW controllers, flexible servo universal inverters, and highly dynamic servomotors close coupled to optional compact servo gear units.

SEW-Eurodrive has released KES37 and RES37 stainless steel gear units that are designed for use where caustic / high-pressure wash downs are required, or where there is potential for product contamination. Klonowski says the new units have casings and shafts made from stainless

Streamlined processes SEW-Eurodrive product manager, Darren Klonowski, says that through improved programming and control, processes can be streamlined by overlapping positioning cycles throughout processes to save time. “This results in productivity improvement because, rather than waiting for a point-to-point task to finish, the motion of many axis can be overlapped to complete the entire positioning task in up to half the time through the use of programmable motion controllers,” he says. 20 www.pacetoday.com.au DECEMBER 2011

steel so there is no need to paint the surface. “This overcomes contamination problems from paint flakes and avoids corrosion, ensuring a long service life. Both models are available with a range of directly mounted stainless steel motors up to 1.5 kW,” he says. NORD Drivesystems AU recently announced the introduction of the NORD Severe Duty (NSD) stainless steel corrosion protection coatings as an option for the NORD helical geared motor and electric motor range. Regional sales manager for VIC, TAS and SA, Tony Sculpher, says that compared to an acrylic paint, the NSD coatings have 40 percent higher impact resistance and twice the surface hardness and corrosion resistance. “These coatings are ideal for almost all food manufacturing plants and are also suitable for chemical wash down and corrosive environments. They also offer the protection of stainless steel at a

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fraction of the cost of a complete stainless steel component,” he said. Other recent releases from NORD Drivesystems AU include the new Screw Conveyor Product (SCP), an innovative range of helical gearbox and geared motors designed especially to fit screw conveyors. “This design eliminates the less efficient and more expensive v-belt drive traditionally used in the screw conveyor industry,” says Sculpher. The latest development in motors from WEG Australia is the W22 high efficiency motor which the company says exceeds the requirements of AS 1359.5–2004 High Efficiency Levels, and reduces energy losses by 10-40 percent compared with other typical MEPS motors. Leandro Mattedi, WEG’s product manager – automation, says the CFW11 variable speed drive makes use of WEG’s extensive experience in motors to develop a truly matched package. “When combined with WEG motors, the Optimal Flux feature can be used to produce full torque at low

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speeds without the need for forced cooling, which is achieved by losses minimisation, resulting in a more efficient package,” he said. “Also, following huge demand to meet the requirements of an explosionproof solution for large motors and machines, the company has launched the EX-p certified range of motors, which means that specific and expensive certification is not required for each individual motor.” ABB 1300 782 527 www.abbaustralia.com.au Nord Drivesystems 03 9394 0500 www.nord.com.au SEW-Eurodrive 03 9933 1000 www.sew-eurodrive.com.au

OPENING: NORD Drivesystems recently opened its facility in Derrimut, Victoria. Assembly of their helical geared motors and electric motors utilises the assembly tooling pioneered by Getriebebau NORD in Germany.

WEG 03 9765 4600 www.weg.net/au

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Dealing with blocked chutes Blockages on conveyor transfer head chutes, wet screens and apron feeders could benefit from a relatively low cost self-cleaning acoustic switch.

UNBLOCKED: The low frequency transducer emits a pressure wave with each pulse that atomises water and fines build-up off the diaphragms.

RELATIVELY new, large export thermal coal mine was experiencing production problems. Located in the Hunter Valley, this mine produces in excess of 10 million tonnes per year. The Coal Handling Preparation Plant (CHPP) was experiencing problems in production because of intermittent tripping of conveyors caused by the blocked chute switches in the head conveyor transfer chutes. The head conveyor transfer chutes are critical to the CHPP plant, as all new coal feed enters through these chutes and conveyors. The problems were caused by coal fines build-up, clay build-up and water sprays in the chutes. This build up was occurring around the blocked chute probes. Each production shift experienced up to six intermittent trips, causing a production downtime loss, of up to 1.25 hours per shift. The cost per hour of lost production was approximately $100,000. The technology specified for the 22 www.pacetoday.com.au DECEMBER 2011

The acoustic switch can be tested remotely through a PLC in critical applications to guarantee the switch’s ongoing capability. (head chute) conveyor transfer chute’s blocked chute switches cost less than $1,000 each. The selected blocked chute switch technology was affected by buildup and false triggering. Clearly, the blocked chute switch selected did not take into account the chute operating environment, cost of downtime for production when originally being specified. Price is a small component in the technology selection for these head chute applications. When specifying a blocked chute switch, Hawk takes into account the operating environment as the most important parameter. The

company supplied the low frequency (15 kHz) acoustic switch with titanium diaphragms that provided a self cleaning capability for the application. The low frequency transducers emit a pressure wave with each pulse that atomises water and fines build-up off the diaphragms. As water allows for the excellent transfer of acoustic sound waves, wet environments actually increase the signal amplitude of the acoustic switch’s ability in conveyor transfer chutes, wet product and reject screens, truck detection, run of mine (ROM) bins and any application where moisture or water spray is used for dust control. The acoustic switch can also be tested remotely, through a PLC, in critical applications, to guarantee the switch’s ongoing capability. Additional alarms can be provided to support routine maintenance of these switches.

The Hawk Gladiator Acoustic Switch has a maximum operating range of 150m depending on the hardware selected. Applications include conveyor transfer chutes, wet and dry screens, reject screens, head chutes, crusher blocked chute switch and boom protection for stackers and reclaimers. Hawk Measurement Systems 03 9873 4750 www.hawk.com.au

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Adjustable compressors A uniform temperature level in the cabinet is obtained for slow changes which causes less stress to the electronic components and the air conditioner.

ANUFACTURERS of air conditioning systems for use in electrical cabinets always look for solutions to reduce energy consumption. Seifert mtm Systems has developed second generation models of the ecool series with speed controlled compressors that promise temperature stability for less component stress, and a higher overall safety combined with significant energy saving. Currently manufacturers try to reduce power consumption by optimising refrigerant circuits and integrating low power fans to reduce electricity costs and make the device more environment-friendly. Because of rising energy costs and efforts to reduce CO2 emissions these efforts are no doubt geared towards the future, especially in large manufacturing facilities with a variety of airconditioned cabinets. But the drawback is that these solutions are still based on a regulating method which merely switches the compressor on and off. So, these systems either run in full power or not at all. In addition, the

compressor always needs a defined standing time between its operation phases before it can start again. The consequences are severe temperature fluctuations and moisture build-up in the cabinet, as well as high stress for the installed components and a heavy load on the air conditioners which can quickly lead to total failure. Together with a major compressor manufacturer, Seifert worked on a speed controlled system that finally does away with these disadvantages. With just three ecool devices and a cooling capacity ranging from 250W to 3,500W, all industrial sizes and requirements – from compact to large control cabinets – are covered. This simplifies the selection of the best-suited air conditioner. The compact compressor, which sets its speed to provide the required cooling performance, only requires the power input necessary for the actual cooling. With the second generation of the ecool air conditioners, a uniform temperature level in the cabinet of up to +/-0.2 K is obtained for slow changes, which causes less stress to the electronic components and the air conditioner.

This results in higher safety and longer life. In addition, the formation of condensation in the cabinet is minimised. Using adjustable compressors increases the Coefficient of Performance (COP) significantly – the current ecool devices which operate in this way reach a COP of up to 2.5 at L35 / L35, while conventional systems achieve only 2.1. As an example, these numbers translate into the following results for the 2,000W class: with only 1,000W of electrical power, a cooling performance of 2,500W can be achieved, whereas other known devices achieve only 2,100W. This means an additional yearly saving average of up to 20 per cent compared to other energy-saving cooling units available at present. Typically, costs and efforts go into installing larger air conditioners if cabinets are upgraded with additional components. This is not needed for an ecool system, since it will adjust to the new setup. Seifert mtm Systems Australia 03 9801 1906 www.seifertsystems.com.au

EFFICIENT: Seifert’s engineering department is able to design tailormade application systems within international quality guidelines.

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DECEMBER 2011 www.pacetoday.com.au 23

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BEHIND THE SCENES

Collaborative future for plant design Autodesk’s recently released Plant Design Suite release showcases the company’s vision for plant design software, writes Isaac Leung.

N SEPTEMBER, Autodesk announced its Plant Design Suite 2012. Robert Shear, Autodesk’s director of industry solutions (construction of plant) spoke with PACE about regarding Autodesk’s vision of the future of plant design. According to Autodesk, process and power distribution are particularly strong markets currently, with projects being developed at a breakneck pace. The amount of work needed to be done is only tempered by a shortage of qualified people. “Work is happening around the world, around the clock,” Shear told PACE. “Every project is a fast-track project, with concurrent design and engineering, and sometimes concurrent design, engineering and construction.” The realities of globalisation have caught up with the plant design process – projects are bigger than ever before, and are executed across multiple time zones and multiple geographies. However, Autodesk says the solutions on the market have been laggard when it comes to playing catch up with the market demands and technology. “Even some of the newer solutions are…cripplingly complex,” Shear said. “Some of them require ten-week training classes just to become proficient in the software.” “The technology is heavy weight, with large databases and large systems…which really have no place in this agile, dynamic world.” Shear says Autodesk aims to improve collaboration, data sharing, useability, and the use of cloud, mobile and reality capture within the plant design market.

Collaboration Depending on which version of the Autodesk Plant Design Suite 2012 a customer purchases, the suite generally include AutoCAD (for general drafting, design and layout), AutoCAD P&ID (piping and instrumentation design), AutoCAD Plant 3D (3D modelling and documentation of piping, with new isometrics features), Revit Structure and 24 www.pacetoday.com.au DECEMBER 2011

DELIVERY: The concept is for all the component tasks involved in plant design to be done in the suite.

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SIMPLIFIED: The spotlight has been thrown on intuitive useability and improved collaboration.

The idea is for all the component tasks involved in plant design to be done in the suite then for the final package to be delivered through AutoCAD.

“Small companies, or companies that don’t have full design packages…can generate isometrics drawings for review, fabrication and mark-up on the hosted solution,” Shear explained. According to Autodesk, this move reflects the fundamental technology shift from the desktop to web and mobile, powered by the cloud. Plant design solutions will become more flexible and portable, while leveraging the processing power of host servers.

Mobile cloud is future Structural Detailing. In the Ultimate version, Autodesk Inventor is also included, for digital prototyping of plant equipment and skids. “By putting our products into a suite, not only does this facilitate much simpler deployment, but we also allow cross-product collaboration and data share,” said Shear. The idea is for all the component tasks involved in plant design to be done in the suite, then for the final package to be delivered through AutoCAD. But Autodesk is not restricting itself to data sharing within the suite. AutoCAD Isometrics, which is used to specify specialised piping for plants, will be one of the first to ascend to the cloud.

Autodesk is investing in mobile, web, cloud and reality capture technologies. Future versions of the Plant Design Suite will integrate reality capture and cloud technologies. Users will be able to take images of plants or equipment with a camera phone, and upload them to the cloud, where the pictures will be turned into a 3D models. “You will be able to walk up to a plant with your iPad and get real-time information regarding the design and cross-correlate that with what you see,” Shear said. Customers will also be able to chat in products with other users in order to improve remote collaboration. Shear says useability is a large part of

Autodesk’s culture, and is built into the products during development. As a result, the Autodesk Plant Design Suite 2012 has an easy-to-use interface backed by an organic approach to training and help, with users encouraged to use online resources and share ideas and learning with the community. Tomislav Golubovic, Plant Solutions Engineer at Autodesk, cited the example of one customer who, after a demonstration of the suite, downloaded a copy of the software, and learned to model pipes and build catalogues and specs by looking at online help and YouTube videos. “This generation of designers expect a Google-like experience, where they can search for things when they need it and get what they need, rather than go through formal training,” Shear said. Of course, formal training is still available through Autodesk or from its resellers. Autodesk is also developing a full curriculum for use by TAFEs.

Australian engagement Autodesk has had a long history in Australia, but Shear says the company is now looking to get re-engaged with the ANZ region. In order to support local standards, specs and catalogues, Autodesk provides

country- or industry-specific content packs for its software. These are available for free download online. While Autodesk has optimised its products for plant designs centred around oil and gas, petrochemical, chemical, and power generation, it is now broadening its offerings. It is particularly extending its reach into areas where there is a lot of Australian demand, such as the mining, water and wastewater sectors.

Better fit Industrial software has long been regarded as clunky, isolated and hard to use. With the latest version of the Autodesk Plant Design Suite, the spotlight has been thrown on intuitive useability and improved collaboration. Autodesk is successfully leveraging the relevant trends from the general computing industry, such as mobile, data sharing and the cloud, to enable plant design stakeholders to respond to today’s challenges. At the same time, it is broadening the capabilities of its solutions to ensure a better fit with the Australian market demands. AutoDesk 02 9844 8000 www.autodesk.com.au DECEMBER 2011 www.pacetoday.com.au 25

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BEHIND THE SCENES

Productivity boost from automation The automation of an aluminium pre-treatment plant has resulted in the doubling of production output, writes Hartley Henderson.

ASED in the Melbourne suburb of Dingley Village, Rylock designs and manufactures high performance energy efficient windows and doors for energy efficient homes. The company recently installed a new plant for the pre-treatment of aluminium sections prior to powder coating. According to Rylock’s design engineer, Peter Kennedy, automation of the plant has resulted in the doubling of production output. The new plant consists of eight large vertical steel towers positioned in a large square pattern, all connected with an overhead structure. Suspended from the overhead structure are two large lifting frames, onto which stainless steel baskets containing aluminium extrusions are loaded. These baskets are then moved automatically through a seven stage pretreatment process. Basic parameters are able to be changed to account for variations in drying time and chemical strength, so the focus is not only on greater throughput but also on greater control of the variables within the process. Kennedy explains that seven tanks are involved in the pre-treatment process. “Tank 1 contains hydrofluoric acid that etches away oxide from the surface of the aluminium sections, while tanks 2 and 3 provide water rinses of increasing purity, and in tank 4 chromate reacts with surface aluminium to form a lattice-like substrate that keys well with powder coating. “Tanks 5, 6 and 7 provide water rinses of increasing purity,” he said. “The pre-treated aluminium sections are then moved to low temperature drying ovens, and then loaded onto the powder coating lines.

The system is contained within safety barriers with various sensors that ensure the system will not operate while there is potential for people to be within that footprint.

MINIMAL INTERVENTION: A view of the acid hoist rising.

CHOSEN: These geared motors were selected to complete a high duty cycle.

Maximum throughput “Previously, 50 percent of one worker’s time was spent with a pendent lifting and lowering baskets through the tanks. Maximum throughput was seven baskets in a day,” explains Kennedy. 26 www.pacetoday.com.au DECEMBER 2011

“The old pre-treatment system was reaching the end of its service life in a factory that was also being outgrown and was operated at its capacity every day. “Maximum throughput of the new

automated system is one basket every 15 minutes. Although not operating anywhere near this capacity yet, the new system allows great flexibility in operation management.

“Pre-treatment previously created a bottleneck that required careful management so as not to effect downstream productivity. “Pre-treatment now requires minimal input from the operator in the areas of loading and unloading. “The new automated system frees up the operator to allow him to perform production duties elsewhere in the factory.”

Safety benefits Kennedy says additional benefits include safety because there is now no need for any personnel to be in close proximity during periods of risk, such as possible chemical splash. “The system is contained within safety barriers with various sensors that ensure the system will not operate while there is potential for people to be within that footprint. “Another benefit is the improved consistency of pre-treated metal. “With this system, time in the reaction tanks (hydrofluoric etch and chromium) is precisely repeated along with exactly repeated draining times and conditions. “The previous system relied upon the timeliness of operator responses to the timer siren, and how cleanly baskets were lifted and lowered on a centre mounted overhead crane setup. Much of the control was left to operator prerogative, attentiveness and skill while also carrying out additional tasks. “Now, parameters can be changed for

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PROCESS: (clockwise from top left) Basket awaiting transfer to drying ovens. Basket being transferred. Lowering basket into acid.

dipping time in reactants, in relation to reactant concentrations, via visual cues (colour of treated aluminium), monitoring feedback, and seasonal conditions affecting drying times.”

Automation technology The control program for the new pretreatment plant commands four separate 0.75 kW frequency inverters, which in turn control four NORD helical geared

motors positioned at the top of each vertical tower of the plant. Tony Sculpher, regional sales manager for NORD Drivesystems AU, advises that the NORD geared motors were each supplied complete with an electromagnetic brake and an incremental encoder for individual positioning feedback to the frequency inverters. “The hollow shaft design and external foot mount gear case provided simplicity to the installation, especially when mounted at the top of each vertical tower,” he said. “These NORD geared motors were selected to complete a high duty cycle and for long life expectancy to help future proof Rylock’s new pretreatment plant. “Rylock’s engineers focussed on making control of the new pre-treatment plant process as simple as possible. For example, a one touch keypad is located on the outside of the control cabinet for ease of operation.” Electrical contractor Proactive, based in the Melbourne suburb of Braeside, was responsible for all electrical

installations for the project. The company’s automation electrician, Ramiro Moran, says this included editing the programming on the AllenBradley PLC and connection of the motors and sensors. “Some careful calculations needed to be carried out, including calculation of the hoist weight in order to ensure the right drive for the plant,” he said. The lifting frames, along with two full baskets can weigh as much as 1,600 kg, so counterweights are utilised to offset some of the mass. Concept, design and mechanical construction of the new pretreatment plant were undertaken inhouse at Rylock. NORD Drivesystems AU 1300 006 673 www.nord.com.au Proactive 03 9584 5188 www.proactivecontrols.com.au Rylock 03 8558 0500 www.rylock.com DECEMBER 2011 www.pacetoday.com.au 27

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SPOTLIGHT

7best of the

PACE showcase of the best engineering technology releases of the month.

USB BitScope Pocket Analyzer BitScope Pocket Analyzer is a unique test instrument combining a powerful Mixed Signal Oscilloscope, Protocol Analyzer, Waveform and Clock Generator, Spectrum Analyzer and Data Recorder in one tiny USB powered device. It offers 10 capture channels (two analogue and eight digital) with 100 MHz analogue bandwidth, 40 MSps logic speed and up to 12 bits analogue resolution as well several output channels for its signal generators, triggers and external control signals. Pocket Analyzer is fast with a frame rate up to 100 Hz driving a digital phosphor display. It works just like a quality stand-alone scope. View waveforms, plots, spectra and more on its smooth flowing real-time screen. Even live capture logic data can be viewed this way. Alternatively large buffers support high speed oneshot capture with post-capture zoom, scrolling and measurement, or it can stream direct to disk for off-line replay and analysis. Software is included for Windows, Mac OS X or Linux. Features include mixed signal, storage and sampling oscilloscopes, logic timing, SPI, CAN, I2C and UART packet decoders, a spectrum analyzer, X-Y phase plotter and data recorder. BitScope Designs 02 9436 2955 bitscope.com/pace

Non-contact electronic safety sensor The Schmersal RSS 36 series is an electronic safety non-contact sensor that provides the highest level of safety (CAT 4, SIL 3, PL e). It provides up to 10 mm sensing distance for applications such as gate or hatch monitoring and position control and protection. Up to 31 RSS 36 safety sensors can be wired in series to CAT 4, SIL 3, PL e. In addition, different variants are available with unique coding. This is enabled by the integration of RFID technology in the safety sensor. The Schmersal RSS 36 safety sensor offers universal mounting possibilities. The materials used for the enclosure have ECOLAB certifications and are resistant to aggressive cleaning agents. It offers IP 69K protection and

designed for use in areas with that use steam jet or high-pressure cleaners. Control Logic 1800 557 705 sales@control-logic.com.au

High-density switching capabilities for PXI National Instruments has introduced eight new relay cards that expand its NI SwitchBlock line of high-density switching solutions for PXI systems. The new cards offer additional simultaneous connections and new differential measurement capabilities for high-channel-count switching applications. Engineers can choose from the expanded selection of NI SwitchBlock cards to create a custom matrix of relays that meets their specific requirements. Designed specifically for demanding automated test systems with large numbers of channels, the NI 28 www.pacetoday.com.au DECEMBER 2011

SwitchBlock cards provide an intuitive option for switch configuration, routing, programming and maintenance in a variety of test applications in military and aerospace, transportation and for general-purpose automated testing. The set of new relay cards includes multiple two-wire switches for differential measurements and 16-row switches that give engineers an increased number of simultaneous connections for large switching applications. National Instruments 02 9491 4000 www.ni.com/switchblock

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Email your product news to editor@pacetoday.com.au

Inspecting bottling lines OmniView is a 360° bottle inspection system capable of an accurate reconstruction of the final image from images received from video cameras placed on the line. OmniView has eliminated the principal weak point of 360° inspection systems, which was dependence on the quality of the final images from the position of the bottles on the line. Using three-dimensional reconstruction, it is possible to generate stable images of the bottles analysed, enabling label checks to be made as if perfectly flattened. A common set-up is to use four cameras that can see the surface of the bottles whatever their position. The OmniView software processes the four images and displays them in a single image compensating for any variation in position during transportation. To inspect a particular feature of interest, it is sufficient to configure the inspection system directly on the whole reconstructed image. OmniView eliminates the costly requirements associated with mechanical rotation of the parts to enable them to be inspected. It is thus possible to reduce the complexity of the production line, lowering the costs and increasing the production rate. OmniView smartview@cognex.com www.cognex.com

Dual-membrane pH electrode for chlor-alkali processes The in-line pH electrode InPro 4850i has been designed specifically for the chlor-alkali industry. It incorporates a sodium-sensitive glass membrane that uses the brine present in chlorine production as a reference. This reference system is hermetically sealed, providing a barrier against oxidising agents that poison other sensors. The InPro 4850i does not have a diaphragm, making it impossible to poison the electrode’s sodium reference system. The design also ensures stable measurement and eliminates sensor drift. The electrode’s pH-sensitive glass membrane is resistant to chlor-alkali process conditions, ensuring

precise pH measurement. The electrodes’ output signals typically suffer from electrical interference. The InPro 4850i overcomes this problem with the use of Intelligent Sensor Management (ISM) technology. Sensors with ISM convert the analogue measurement signal into a low-impedance digital signal which is immune to electrical interference. ISM also enables sensor self-diagnostics and pre-calibration as well as plug and measure start up to simplify installation and maintenance tasks. Mettler Toledo 1300 659 761 www.mt.com

Humidity and temperature log The humidity and temperature HygroLog HL-20/21 data logger from Rotronic expands on the HygroLog family of products. The new logger utilises AirChip 3000 technology and HygroMer sensors. When combined with HW4 software, all FDA, CFR 21 part 11 and GAMP regulatory requirements are fulfilled. Applications include pharmaceutical clean rooms, warehouses, production rooms, transportation containers, museums and test facilities. Programming, downloading and graphing of recorded data is uncomplicated with the HW4 software. The HygroLog HL-20/21 has a memory capacity of up to 20,000 data points. Additionally, the HygroLog HL-20/21 has the option of recording both dew/ frost points. All recorded data is date and time stamped. The HygroLog HL-20/21 has an accuracy of 0.8%RH and 0.2°C. Pryde Measurement 1800 688 211 sales@pryde.com.au

Thermal imager in camcorder format The testo 885 comes in the newly developed camcorder format with a rotatable handle. It features a wide angle or telephoto lens, 320 x 240-pixel detector and a noise-equivalent temperature difference or NETD less than 30 mK. The built-in SuperResolution technology delivers a fourfold increase in thermal image resolution. If the illustration of the measurement object in building thermography is not possible with a single image, the testo 885 offers a panoramic image which presents one view that is created from several individual images. The

patent-pending SiteRecognition technology can be used to support the efficient completion of inspection routes. This automatically takes care of the recognition of measurement sites and the storage and administration of the thermal images. The possibility of taking measurements in temperature ranges up to 1,200°C allows the unit to be used in a wide range of industrial applications. Testo 03 8761 6108 www.testo.com.au DECEMBER 2011 www.pacetoday.com.au 29

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EVENTS & EDUCATION

WHAT’S ON

TOP TWEETS

Practical Motor Protection, Control and Maintenance Technologies Workshop 5-6 December 2011, Perth www.idc-online.com Project Engineering - Fundamentals of a Project Lifecycle 5-7 December 2011, Perth www.icheme.org/projeng Advanced Hydraulic Fracturing for Shale Gas Drilling Operations 12-13 December 2011, Houston www.fractraining.com

Here’s what you may have missed this November if you weren’t following @pacetoday on Twitter: ❏ Shark found in seawater intake station at Perth Desalination Plant. http://dlvr.it/wD2zR

❏ NSW researchers receive funding to develop search and rescue robots. http://dlvr.it/tDP2J

❏ Process industry focuses on energy management and resource efficiency. http://dlvr.it/tyxCs

❏ EndressHauser acquires stake in Finesse Solutions. http://dlvr.it/tG9j3

❏ Dassault Systemes acquires Elsys. http://dlvr.it/tytkB

❏ Santos secures new gas supply contract to Murrin Murrin. http://dlvr.it/tb73v

❏ ABB to acquire Powercorp in Australia. http://dlvr.it/wD7dQ ❏ Siemens acquires engineering software company Vistagy. http://dlvr.it/wNbdr

Water Management in Mining 6-8 December 2011, Perth www.waterinmining.com.au

❏ ACT research fabrication facility set up to boost innovation in manufacturing. http://dlvr.it/tGJ95 ❏ $25m funding for Geelong Geothermal Power Project. http://dlvr.it/tQltb

❏ CSIRO releases "Water" book. http://dlvr.it/txpyL

Flow Assurance and Integrated Production Technology 26-29 February 2012, Abu Dhabi www.flowassuranceme.com

❏ Government to fast track 457 visas. http://dlvr.it/tPbkt

❏ Benefits of using thermal imaging cameras in the food industry. http://dlvr.it/sxZcc

❏ GE consortium to build coal seam gas salt extraction plant in South Australia. http://dlvr.it/tDYM7

For daily updates visit www.pacetoday.com.au

Follow @pacetoday on Twitter for the latest news, analysis, new product information and commentary. And never miss out again.

IICA NEWS & VIEWS

Solutions Expos in 2012 The IICA brainstrorming sessions threw up interesting ideas, writes Brett Simpson. THE IICA Federal Council met in Sydney on 28 - 29 October for the second of this year’s two In Person Meetings. Attended by IICA Branch Representatives and Office Bearers, this meeting comprised brainstorming sessions on the way forward for the IICA. The IICA / ISA Professional Development Courses have had various degrees of success throughout 2011 but unfortunately a number of courses were cancelled due to insufficient registrations. This has been the case since the GFC but the last few courses of 2011 have attracted a good number of registrations. The IICA Training Manager, Graham Moss, is looking into the viability of some of the courses to see whether they really fit into what the IICA wants to 30 www.pacetoday.com.au DECEMBER 2011

provide to its members. The course calendar will be available in early 2012. In early 2011, the IICA attended an Engineers Australia Careers Expo held in Melbourne and were surprised and delighted by the number of people asking questions about the IICA and the industry in general. The IICA is planning to have a stand at the Melbourne, Sydney and Perth Careers Expos in 2012. The Federal Council discussed some additional awards for people or companies who have done great things for the industry. Further information will be available in 2012. The IICA 2012 Event Calendar is now available on our website. In 2012, Federal Council has decided to trial some ‘Solutions Expos’ to attract more

The Federal Council discussed some additional awards for people or companies who have made significant contributions to the industry and the Council will provide further information in 2012. attendees at our Exhibitions. The Solutions Expos will have some short presentations detailing solutions to

specific problems rather than a general ‘sales spiel’. The Sydney Technology Expo will also include a Solutions Expo but the focus on the whole Event will be on Flow Technology. The IICA Standards Sub Committee will be looking into how we can become more involved in Standards Committees related to the Instrumentation, Control and Automation Industry. At the moment, a small number of IICA Members represent the IICA on a few select Standards Committees. We will be looking to increase this. [Brett Simpson is IICA Federal President.] Institute of Instrumentation Control and Automation (IICA) 03 9036 0166 www.iica.org.au

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PACE ZENITH

AWARDS 2012 NOMINATIONS

NOW OPEN The PACE Zenith Awards recognise companies and professionals who show innovation in engineering projects and technological excellence in one or more of ten industry categories. Submit your entry and you can see your success and hard work rewarded at a glamorous gala event in Melbourne on 14 June 2012. WHY NOMINATE? • Exposure and publicity • Recognition for your hard-working team members • Valuable networking opportunities with key industry leaders

ATIO NOMIN E CLOS

L 2012 I R P A 1

CATEGORIES: Automotive & Manufacturing Food & Beverage Metal Products Manufacturing Mining, Minerals & Exploration Oil & Gas Power & Energy Management Lifetime Achievement Award Transport, Power & Infrastructure Water & Wastewater Young Achiever

Visit www.pacetoday.com.au/awards to download the entry kit.

Sponsorship opportunities are available:

For further information please email kevin.gomez@reedbusiness.com.au

Contact Tim Richards on (02) 9422 2818 or tim.richards@reedbusiness.com.au

PROUDLY SPONSORED BY:

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Introducing a smarter way to calibrate temperature

Beamex® FB Field Temperature Block Beamex® MB Metrology Temperature Block Beamex introduces a smarter, more efﬁcient and accurate solution for calibrating temperature. Beamex® has two different dry block series: the Beamex® FB Series Field Temperature Blocks and the Beamex® MB Series Temperature Metrology Blocks. The dry blocks in the FB Series are lightweight, high-accuracy temperature dry blocks for industrial ﬁeld use. The dry blocks in the MB Series deliver bath-level accuracy for industrial applications.

Portable calibrators Workstations Calibration software Professional services Industry solutions