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

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PACE PROCESS & CONTROL ENGINEERING

Energy audits are key Energy audits are the foundation of an effective energy efficiency program. Opinion 4

Zenith winners revealed Profiles of the people and projects that walked away with the trophies. Special Report 6

Top honours for APC project ZZZ DQ\EXV FRP DX JULY 2011

VOL.64 NO.6

INSIDE THIS ISSUE

News 3

Cloud computing The benefits of cloud computing are still being weighed against the risks. New Products 28

7 of the Best This month’s round-up of noteworthy new products. IICA News & Views 30

Hurdles in training Most Universities and TAFEs do not offer stand-alone qualifications in Instrumentation.

BY KEVIN GOMEZ APEX Optimisation and Woodside Energy's revamp and implementation of the Advanced Process Control (APC) at Karratha Gas Plant has won PACE magazine’s overall project of the year award. The execution of the project was very challenging due to a range of factors because the team pursued a design evolution which widened the scope of the APC significantly beyond the original LNG4 APC implementation with additional handles, limits and configuration challenges. Additionally, the size of the new applications, with each having more than 20 manipulated variables managing in excess of 60 controlled variables, meant some complex interactions had to be modelled. The APC delivered the North West Shelf Project Partners a 3 to 5 percent increase in LNG4/5 production (depending upon ambient conditions) and a 4.7 percent increase in LPG production. These verified benefits meant the period for overall project payback was less than two weeks, with a ROI of 4,000 percent. The judges noted that “this excellent implementation of Advanced Process Control has rewarded the business with exceptional returns.”

CONGRATULATIONS: Overall project winners Paul Kjellgren of Woodside Energy flanked by Apex Optimisation’s Ian Johnston (L) and Andrew Taylor.

INDUSTRY NEWS

IICA and PACE join forces to grow and support the industry

Post Print Approved PP255003/00539

AUSTRALIA’s process control and automation industries face several challenges but none more daunting than those related to skilled resource, education and training. The Institute of Instrumentation Control and Automation Australia (IICA) has been

doing its bit to train professionals and support the industry. “At PACE, we share IICA’s vision,” says Kevin Gomez, Editor, PACE. “Our involvement with the industry spans nearly six decades and we are keen to work with the IICA to grow, educate and

enrich the communities we serve.” Following the exclusive agreement that was finalised between the two parties mid June, the IICA will use PACE to promote its activities and reach its members. “This agreement is a natural extension and in reality, a formalisation of

the long standing arrangement that the IICA has had with the PACE,” noted Brett Simpson. “This agreement brings to fruition a genuine partnership that seems in retrospect something that should have happened a long time ago,” he adds.

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NEWS

EDITOR’S MESSAGE

PACE

Joining forces

PROCESS & CONTROL ENGINEERING

Published monthly by Reed Business Information Pty Ltd Tower 2, 475 Victoria Avenue Chatswood NSW 2067 Locked Bag 2999 Chatswood DC NSW 2067 Tel: (02) 9422 2999 Fax: (02) 9422 2977 ABN 80 132 719 861

Publisher: Michelle Graves Email: michelle.graves@reedbusiness.com.au Editor: Kevin Gomez Tel: (02) 9422 2976 Fax: (02) 9422 2722 Email: kevin.gomez@reedbusiness.com.au

Kevin Gomez Editor

Senior Journalistt: Isaac Leung Tel: (02) 9422 2956 Email: isaac.leung@reedbusiness.com.au Account Manager: Tim Richards Tel: (02) 9422 2818 Mobile: 0407 948 774 Email: tim.richards@reedbusiness.com.au QLD Sales Manager: Sharon R. Amos PO Box 3136, Bracken Ridge, QLD 4017 Tel: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 Email: sharon.amos@reedbusiness.com.au New Business: Alex Evans Tel: (02) 9422 2890 Email: alex.evans@reedbusiness.com.au Graphic Designer: Elliott Hind Email: elliott.hind@reedbusiness.com.au Production Coo-ordinator: Jennifer Collinson Tel: (02) 9422 2657 Fax: (02) 9422 2722 Email: jennifer.collinson@reedbusiness.com.au

Next Issue Motors, Drives and Motion Control ● Wireless Technology ● Process Control in Oil & Gas ●

FIRST, hearty congratulations to all the winners of the Zenith Awards. You have done your companies proud and turned the spotlight on the innovative work that is being done right here in this country. To all the finalists, I must stress that it was very close with very little separating the winners from the rest in many categories. We hope to see you again next year when the Zenith Awards function moves to Melbourne. The winner of the Overall Project of the Year – Apex Optimisation and Woodside Energy –was deemed an exceptional success. It was completed on schedule and within budget despite an evolving design datum throughout execution. The judges noted that there was high operator involvement and acceptance throughout the project, with APC uptimes consistently surpassing 97 per cent. With the APC maintaining the process within the desired operating envelope on a minute by minute basis, the LNG trains Karratha Gas Plant experienced improved reliability, decreased energy consumption and carbon footprint and increased production. At PACE we’re also pleased to have

entered into an exclusive agreement with the IICA. Between the two organisations, we have a hundred years in the process control and automation industry and we’d like to ensure its growth and development in the period ahead. With this arrangement in place, the IICA will be able to better promote its training courses and events. They will be in a position to reach further and wider into other key industry sectors using PACE, and where relevant, other titles published by PACE magazine's parent company, Reed Business Information. In turn, PACE readers will have exclusive access to quality technical content culled from ISA/IICA training and presentations thereby cementing its leadership position in the market. Brett Simpson is the new Federal President of the IICA. Both of us believe that PACE will be a good fit for the IICA. The kind of readership that PACE attracts is synergistic with IICA’s individual and corporate member audience. This agreement between the two organisations will be a winwin for both. Kevin.Gomez@reedbusiness.com.au

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Emergence of cloud computing in automation BY JIM PINTO IN THE automation world, the benefits of cloud computing are still being weighed against the risks. Process managers and automation engineers are averse to putting their operating software and plant information on remote servers, primarily because of perceptions of reduced security, questionable availability and uncertain location, even though company-owned servers are already somewhat distant and inaccessible. The use of virtualised servers is becoming attractive for end users. Already, fewer, larger servers are being

used to run multiple applications such as workstations, historians and HMIs, and those are mostly remote in any case. Moving to cloud servers has many advantages beyond just space consolidation. In any event, moving an actual DCS to the cloud is not likely to happen quickly. However, secondary processes and systems such as HMIs, historians, training systems and engineering workstations may well be moved, albeit tentatively, as plant managers become more comfortable with the concept. The integrated information model must span the entire enterprise regardless

of size, geography or complexity, integrating multiple tiers of information – manufacturing execution systems, automation systems and enterprise applications – to drive planning and execution closer together. Cloud-based applications and information exchange is the best way to service this new global infrastructure. The key point that fuels doubts is: How secure (safe and spyproof) is the remote data? Amazon, one of the largest suppliers, recently had a widespread outage that temporarily crippled some of the highly trafficked websites and data centres it hosts. Jim@JimPinto.com

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OPINION

VIEWPOINT

Audits provide a benchmark Energy audits create a focus for many organisations, writes Sal Spada.

OR most manufacturing and other industrial operations, environmental responsibility is not new. Many manufacturers around the world have had programs and policies in place for fifty years. If anything, manufacturers in Australia, who have reduced their energy consumption via a combination of new technology and fuel switching, are a little ahead of this curve. However, new pressures, driven by energy price volatility and regulation, create an even stronger correlation between energy efficiency and environmental responsibility. Manufacturers are beginning to see significant new constraints, regulations, and

4 www.pacetoday.com.au JULY 2011

climate issues as business drivers. This will only escalate. We’re likely to see higher prices for carbon emissions, with implications for product composition, documentation, and transport. As a result, energy efficiency remains a key concern for manufacturers in Australia, particularly for those in the more energy-intensive mining, ferrous and non-ferrous metals processing, and refining industries. To best prepare for higher energy prices and more restrictive regulations, a company should perform an energy audit or plant assessment that will be used as an initial benchmark for energy improvement initiatives. Developed nations that have long been subjected to

energy price volatility, have realised benefits from energy audits, which have drawn attention to comprehensive energy management practices and equipment retrofits. In Australia and New Zealand, the AS/NZS 3598:2000 standard is available to industrial (and other) organisations to help them: • Decide what level of energy audit is appropriate for their needs • Provide a guide for energy users when commissioning energy audits • Provide a uniform basis for preparing and comparing energy audit proposals • Establish best practices for auditors • Help establish an energy management program by specifying pre- and postaudit activities and appropriate reporting • Define requirements for the audit, and • Contribute to the quality of existing energy and other management systems Energy audits provide the foundation for developing an effective energy efficiency program and create operations that are more efficient. The most significant obstacle to overcome in any organisation is simply cutting across cultural divides in operations that have access to capital budgets. Energy audits and plant assessments, especially those conducted by independent third parties, provide objective analysis on where limited capital can be employed most effectively to achieve energy goals. Numerous industry and government resources can provide assistance. Operations must recognise that energy is a controllable operating expense and should be managed with the same expertise and resources as other parts of the business. Robust energy management processes, procedures, and practices are as effective at saving energy as are technological solutions. An energy ‘health check’ helps companies assess their energy management practices relative to global best practices. It also helps identify opportunities for further improvement when used as a continuous improvement tool. Energy audits provide a focused approach that

Energy audits provide the foundation for developing an effective energy efficiency program.

targets specific types of systems throughout the operation that can be upgraded or replaced. Monitoring major systems’ energy consumption and correlating energy consumption with time of day and production delivers important information to support planning, scheduling, and equipment upgrade plans. The latest generation of operations scheduling algorithms explicitly take into account energy consumption and carbon dioxide generation. With the advancement of wireless technologies, energy monitoring equipment can be installed in a cost-effective manner in an existing facility. Process data collection in 15 minute increments is generally sufficient for managing energy and setting targets per unit produced that will help identify and reduce waste. To remain competitive, businesses must identify bottlenecks and remove constraints facing energy management initiatives. Energy consumption measurements and metrics will need to be put in place to help reduce energy consumption by using energy-versusproduction as the key metric. In addition to new metering and data collection devices, new software functionality will be required to make the detailed production energy consumption visible to enable better decision making and control. Energy audits have created focus for many organisations. Several full-line automation suppliers now offer energy audit services within a larger energy management portfolio. [Sal Spada (SSpada@ARCweb.com) is Research Director, ARC Advisory Group.] www.ARCweb.com

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PACE ZENITH AWARDS 2011 WINNER

Innovation recognised at Zenith Awards WINNERS

AKE an already successful awards event, add two ‘people’ categories to the mix of project entrants, get a noted energy expert to enthral the audience, throw in a slick MC and we have an evening that will be remembered for a very long time. PACE magazine’s 8th annual Zenith Awards dinner on 16 June 16 2011 in Sydney welcomed a record number of finalists – as well as attendees. In the end it was the projects, the people and the supportive sponsor companies that helped make this event a reality. There is a lot of coverage of the Zenith Awards on our website, so head over to www.pacetoday.com.au and check out detailed profiles of the winning projects and people. The winners in each category are:

POWER & ENERGY MANAGEMENT K E Brown Electrical Switchboards for Darling Walk Redevelopment FOOD & BEVERAGE Zi-Argus NSW for Boags Brewery Modernisation and Expansion

OIL, GAS & HYDROCARBONS Apex Optimisation and Woodside Energy Limited for LNG Train Advanced Process Control METAL PRODUCTS MANUFACTURING Xstrata Copper for ESP Dust Recovery Plant

MINING, MINERALS & EXPLORATION Coal Services Pty Limited for Virtual Reality Training TRANSPORT, POWER & INFRASTRUCTURE Hero Engineering for DiCOM Project Development WATER & WASTEWATER Wide Bay Water Corporation for Nikenbah Wastewater Treatment Plant YOUNG ACHIEVER AWARD Brad Shaw from Serck Controls

LIFETIME ACHIEVEMENT AWARD Mario Dona from Santos Ltd AUTOMOTIVE & MANUFACTURING The Dulux Group & Robotic Automation for Robotic Compositing, Handling & Stocking System PROJECT OF THE YEAR Apex Optimisation and Woodside Energy Limited for LNG Train Advanced Process Control

OCCASION: Professor David Hill enthralled the audience at the Zenith Awards dinner in the elegantly set up Doltone House.

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PACE ZENITH AWARDS 2011 WINNER

Metal Products Manufacturing WINNER

Xstrata Copper ESP Dust Recovery Plant Mt Isa, Queensland This project deals with the numerous issues associated with the copper smelter by-product – ESP dust. Electrostatic precipitator (ESP) dust is formed as a by-product of the copper smelting process. ESP dust is an environmental hazard; it presents a serious hygiene risk to humans, creates a dusting issue and takes up valuable real-estate on the mining lease when stockpiled. A large stockpile of ESP dust has been accumulated over approximately 16 years of smelter operation. Aside from the hazards, a considerable opportunity exists as the ESP dust contains valuable copper and gold. Brett Harries, Smelter Business development manager with Xstrata Copper, said the operation faced many challenges. “The issue with the project was the material is actually a by-product from the smelting process. It has a lot of minor elements in it which are harmful for the environment,” he told PACE.

“Over the years of operation we accumulated about 130,000t of this material. We had to deal with two things: overcoming the environmental aspect, the liability there, so we could comply with our own sustainable development standards, as well as unlocking the significant opportunity associated with the copper and other base metals that were locked up in that material.” “There was the need to develop a very unique technology to reclaim the material and transport it to a newly designed plant. And there was another specific control around controlling the pH of the dust once it’s in solution to a very tight band, where it will allow the recovery of the value-add material, but at the same time, allow us to separate out the harmful minor elements, stabilise them, and then stored.” It is forecast that all arising and stockpiled dust will be consumed by the middle of 2011 after commissioning of a second Agitruck. As a result an additional 20kt of copper and 18koz of gold that otherwise would have been written off will be recovered.

WINNER: Brett Harries (R) and Peter Woodall, both from Xstrata Copper, Mount Isa Mines, take home the winner's trophy in the Metal Products Manufacturing category.

Advan-Touch: Out Of The Box, Install And Connect! Wonderware and Advantech are combining their leading products InTouch visualization and Windows XP Touch Panel Computers to provide the most cost effective SCADA/HMI TPC offering. This unique offering delivers pre-installed Operator Interface units that beneﬁt users as follows: • • • • • •

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PACE ZENITH AWARDS 2011 WINNER

Power and Energy Management WINNER

K E Brown Electrical Switchboards Darling Walk Redevelopment Sydney, New South Wales KE Brown's (KEB) switchboard design was used to overcome potential electromagnetic field (EMF) hazards at the $560 million Darling Walk regeneration project. The 6-star Green Star design rated Darling Walk project comprises two commercial buildings. KEB supplied all the switchboards required on the project to communications, electrical, data and HVAC services supplier Fredon, which was responsible for the complete electrical installation for this project, from the base fit-out to the subsequent integration and fit-out of all 16 floors. Speaking of the win, Steven van der

Mye, chairman of K.E. Brown Electrical Switchboards, said the quality of the company's products makes it unique. "K E Brown makes about one in four low voltage switchboards in NSW, and we've been around for 63 years. It's all about the technology, it's about the differentiating quality of the product," he told PACE. "A lot of people designate us to make their boards, so it doesn't even go out to tender, because of the quality that's built-in. We're an ISO 9001 certified organisation, so quality is built in all the way and not added on in the end." The judges said: "This project employs an excellent understanding of the designs and manufacturing standards required to respond to more stringent benchmarks for EMF emissions."

WINNER: Steven van der Mye (L), Chairman, K E Brown Electrical Switchboards receives the Zenith Award from category sponsor Paul McRoberts, Rockwell Automation - Industry Solutions Manager, South Pacific.

JULY 2011 www.pacetoday.com.au 9

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PACE ZENITH AWARDS 2011 WINNER

Food and Beverage WINNER

Zi-Argus NSW Boags Brewery Modernisation and Expansion, Tasmania While much of the focus of the brewing process has been on standardising batch process control, alignment to the S88 standard and robust engineering practices have provided a vehicle for uniformly implementing similar solutions to different processes within the sites. Lion Nathan required a Standard Automation Philosophy to underpin ongoing significant capital investments. Zi-Argus NSW implemented these concepts at the Boags site for the Brewhouse, Filtration and Bright Beer production areas. Speaking to PACE after the win, Ken Maxwell, sales director of Zi-Argus NSW, said the flexibility of the upgrade

was a key point. “Our project was redefining the control strategies for Lion Nathan’s breweries, and that was based on a new structured batch control system, which was developed as an international standard,” he explained. “It was applied by the breweries to do what was traditionally done in a way that was bespoke for that application. So we went from a bespoke to an application which was based on an international standard. That gave us the ability to roll it out to many breweries.” The judges commented: “This is a well designed and executed project. The design was able to place the process owners back in control of the process. The powerful concept of ‘one click’ manufacturing was successfully implemented in a brewery.”

WINNER: Ken Maxwell (L), Sales Director, Zi-Argus NSW receives the winner’s trophy from sponsor Sean Cahill, Regional Sales Manager, Siemens.

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PACE ZENITH AWARDS 2011 WINNER

Mining, Minerals & Exploration WINNER

Coal Services Pty Ltd Virtual Reality Training New South Wales Virtual Reality (VR) Training is a business unit of Coal Services. The VR is suitable for the advanced training of mine workers and operators who are required to perform potentially dangerous tasks often in hazardous environments in safer surroundings. The appeal of the VR as a training tool is also conductive to the type of social environments that many young workers are accustomed to through their various day to day computer based interactions from gaming through to banking. “We have received a number of requests from the US and China for tours of our facilities and guidance regarding the implementation of equivalent hi-tech training systems,”

said Bruce Dowsett, manager of Virtual Reality Training at Coal Services. The company has now progressed to a ‘next generation’ product with innovations that are taking VR Training to a higher level – including improved fidelity and interaction. The integration of off-the-shelf hardware with the software was key. “Putting those together to achieve top quality training has been the biggest challenge that we’ve had. It’s taken three generations of technology to do it but we have now done it,” remarked Dowsett. The judges said: “This project represents an important development in simulation for needs-based training for operator workplace and safety management. This well-conceived program can play a major role in protecting and training the mining industry.”

WINNER: Bruce Dowsett (R), Manager of Virtual Reality Training, Coal Services receives the Zenith Award from category sponsor Scott Wooldridge, Vice President, Schneider Electric.

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PACE ZENITH AWARDS 2011 WINNER

Automotive and Manufacturing WINNER

Robotics Automation and The Dulux Group Robotic Compositing, Handling & Stocking System Dandenong South, Victoria A ROBOTIC system developed by Dulux Group and Robotics Automation was implemented to assist workers handling hazardous powders. The challenge arose on account of the need for several complex powder ingredients for a customised powder-coat process. This required Dulux Group staff to handle and decant loose, heaving bags of powders, in different sizes weighing 20-25 kg each. Three Robotic Chefs have now been set up to stock, handle, pour, mix or more basically to cook up a perfect

powder-coating product to order. Speaking of the win during the awards night, Colin Wells, managing director of Robotic Automation, said combining consistency with automation was a big challenge. “We faced the challenge of getting many different ingredients to all mix up in exactly the right recipe for somebody’s paint, in any part of the country, so when it’s slapped on a wall, it’s the same colour as the others. That’s the challenge, trying to do that automatically.” The judges said: “This is a well engineered solution to improve productivity and workplace safety. It redeployed workers out of hazardous work areas. “This is a good implementation of automated manufacturing delivering tangible benefits.”

WINNER: Category sponsor Dave Delany (L), Managing Director, ifm efector presents the trophy to Colin Wells, Managing Director, Robotic Automation.

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JULY 2011 www.pacetoday.com.au 15

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MASTERCLASS

A New Guide to Successful Differential The availability of Electronic Remote Sensor technology enables the use of DP Level instrumentation on tall

ERS delivers unmatched benefits when used on the right applications.

MERSON Process Management has released the industry’s first digital DP Level architecture, the Rosemount 3051S Electronic Remote Sensor system. With over ten patents, the 3051S ERS system is a breakthrough technology that replaces mechanical impulse piping with two 3051S pressure sensors that are linked together electronically. Differential pressure (DP) is calculated in one of the two sensors and is transmitted using a standard two-wire 4-20 mA HART signal.

Overview of Traditional DP Level Technology Conventional differential pressure transmitters are used in level applications by measuring the amount of pressure exerted by the liquid level in a vessel. For example, a 500 mm column of water will exert 500 mmH20 of pressure. However, in many applications, there is additional vapour pressure above the liquid. Being that the vapour pressure is not part of the liquid level measurement, the use of impulse piping or capillary with seals is required to compensate for its presence. In an impulse piping configuration, 16 www.pacetoday.com.au JULY 2011

the low side reference leg is either filled with a column of liquid (wet leg) or with a suitable dry gas (dry leg). Wet legs are used when the vapour in the tank will condense into liquid form. Likewise, dry legs are used when the vapour does not condense. While relatively simple in concept, impulse piping installations can be difficult to maintain. Evaporation often occurs in wet legs and condensation can occur in dry legs. Both conditions will cause measurement error in the DP transmitter. Additionally, impulse lines can leak, plug, and may require insulation or heat tracing. Capillary and seal systems eliminate many of the issues with impulse piping installations. These systems consist of external sensing diaphragms that are connected to the DP transmitter with oilfilled capillaries. Changes in pressure cause the diaphragm membrane to deflect, and the pressure is transferred through the oilfilled capillary to the transmitter. Oil-filled capillary systems are carefully welded and manufactured so that it is a hermetically closed system for reliable performance. This type of construction eliminates leak points and plugging that can occur with impulse piping, and there is no need to fill or drain the lines.

Capillary and seal systems consist of external sensing diaphragms connected to the differential pressure transmitter with oilfilled capillaries. A common capillary seal configuration is the “balanced system”, where the seals and capillary length are identical on both the high and low side of the DP transmitter. This type of system is traditionally specified because it supposedly compensates for all temperature effects. For example, as the outdoor temperature changes (whether from night to day or season to season), the oil volume in the capillary will expand and contract, causing changes in the internal pressure of the capillary system. These changes in pressure will result in measurement error, called “seal temperature effect”. A balanced symmetrical system was initially thought to cancel out this error, because the same expansion /

contraction of oil volume will occur on both the high and low sides of the transmitter. While this may be true, there is another source of temperature error that is not addressed. Anytime a capillary seal system is installed and there is a vertical separation between the two seals (such as on all vessels and distillation towers), there is “head pressure” that is exerted on the low side of the transmitter from the weight of the oil in the capillary. Again as the temperature conditions change, the density of the oil in the capillary will fluctuate and cause a change in the head pressure that is measured by the transmitter. This source of error is called “head temperature effect.” While balanced systems can cancel out seal temperature effect, they do not compensate for head temperature effect. Additionally, balanced systems result in extra capillary on the high side of the transmitter that is often coiled up and adds unnecessary costs. Balanced systems also require the use of a pipe stand or other mounting hardware to facilitate the installation of the transmitter. Rosemount Tuned-System assemblies offer a better solution compared to balanced systems by offering improved

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PRESENTED BY

Pressure Level Measurement vessels and distillation towers, writes Michael Olivier.

performance and easier installations at a lower cost. Tuned-System assemblies consist of a direct mount seal on the high-side of the transmitter with a single length of capillary and seal on the low side of the transmitter. The asymmetrical design purposely induces seal temperature effects to counteract the head temperature effects that will always be present on any vertical installation. Also, Tuned-System assemblies can be directly mounted to the vessel without the need for additional transmitter mounting hardware, and installed costs are often reduced by 20% by eliminating the unnecessary length of capillary on the high side of the transmitter.

Limitations of Traditional DP Level Technology While Tuned-System assemblies are a proven and reliable technology, tall vessels and towers have traditionally been difficult applications. In particular, these require longer lengths of capillary to facilitate the installation, resulting in head temperature effects that are often too great to “tune” out. For example, an installation that requires 50 feet (15 meters) of capillary will experience as much as 15 in.H20 (383 mmH20) of measurement drift for a 50°F (28°C) change in temperature. Additionally,

LEARN MORE

Additional information on the Rosemount 3051S ERS System including videos, success stories, and product specifications can be found online at http://www.Rosemount.com/3051S ERS

time-response can be sub-optimal on tall vessels and towers, and installations become increasingly difficult with longer lengths of capillary.

Electronic Remote Sensor Technology Electronic Remote Sensor technology solves many of the problems that are traditionally seen when making a DP measurement on tall vessels or towers. Rather than using a single DP transmitter with mechanical impulse piping or capillary, the Rosemount 3051S ERS System uses two direct mount gage or absolute sensors that are connected with a non-proprietary electrical wire. One of the two sensors calculates the DP and transmits it back to the host system / DCS using a standard two 4-20 mA HART signal. Various configurations are possible for DP level measurement.

ERS is the digital architecture that eliminates the mechanical limitations of capillary solutions.

The unique digital architecture of the 3051S ERS System enables many benefits when used on tall vessels and distillation towers including: • Improved Performance: The 3051S ERS System replaces mechanical components with a digital architecture, resulting in faster time response and a more stable and repeatable measurement even in applications with wide varying temperatures. • Simplified Installations and Maintenance: Cold weather installations often require heat tracing or insulation. Impulse lines need to be checked for leaks, condensation, evaporation, and plugging. The digital architecture of the 3051S ERS System eliminates these practices, resulting in cleaner installations with less maintenance and upkeep. • Additional Process Insight and Diagnostics: The 3051S ERS System is a MultiVariable solution that provides additional process information for optimised control. In addition to the DP calculation, the 3051S ERS provides real-time access to the read-

ings from each pressure sensor and a scaled output for tank level or volume measurement.

Complimentary Technologies While the 3051S ERS System is great for tall vessels and towers, there are applications where a traditional TunedSystem assembly will continue to be the preferred technology. The sensors in a 3051S ERS System are specified and sized based on the combined static pressure and the DP column from the liquid level, where as a Tuned-System assembly is sized just on the DP column. Because of this, Tuned-System assemblies will continue to be the optimal solution for smaller, higher pressure vessels, and Electronic Remote Sensor technology will enable new success on tall vessels, towers, and other similar applications. [Michael Olivier is Senior Marketing Engineer, Emerson Process Management.] Emerson Process Management Australia 1300 55 3051 info.aus@AP.EmersonProcess.com www.EmersonProcess.com.au JULY 2011 www.pacetoday.com.au 17

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Memosens connecting partners Memosens bridges the gap Memosens digital sensor technology bridges the gap in analytical measurement. It solves the problems of moisture ingress, leakage and corrosion with inductive, contactless sensor-cable connections. Reliable, interference-free data transmission â&#x20AC;&#x201C; and most importantly, process safety â&#x20AC;&#x201C; is guaranteed. Plus its robust transmission signal removes the need for pre-amplification or expensive cabling. And its digital memory stores calibration data for true plug-and-play capability. Now there are Memosens sensors covering most analytical process control and asset management systems. The gap in analytical measuring is finally closed. Endress+Hauser Australia Pty Ltd Unit 8, 277 Lane Cove Road North RydeLink Business Park NORTH RYDE NSW 2113

Phone +61 2 8877 7000 Fax +61 2 8877 7099 info@au.endress.com www.au.endress.com

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PACE ZENITH AWARDS 2011 WINNER

Water and Wastewater

PROFIBUS

WINNER

REFINE THE PROCESS

WINNER: Tim Maloney (R), Manager of Electrical Engineering, Wide Bay Water Corporation receives the Zenith award from category sponsor, Greg Ferrar, Marketing Manager, Endress+Hauser Australia.

PROFIBUS International Competence Centre

Wide Bay Water Corporation Nikenbah Wastewater Treatment Plant Hervey Bay, Queensland Nikenbah Wastewater Treatment Plant was specifically designed with lowmaintenance, low-pressure membrane technology for the advanced removal of nutrients from wastewater and the actual results achieved are even better than initially predicted. Acting as the principal contractor, Wide Bay Water Corporation sought to avoid issues they had encountered previously when multiple vendors used different equipment, requiring a large number of spare parts. This time, they looked for a single supplier who would be able to deliver a fully-integrated, high-availability process automation solution cost effectively in order to ensure a lower TCO. Using Schneider Electric’s PlantStruxure hardware, software and support, system integrators Conneq i.Power Solutions designed and implemented the electrical and process automation infrastructure for the plant. Even before it went into operation, the plant at Nikenbah won top award

from the Institute of Public Works Engineering for “water industry projects over $10 million” and now has a Zenith Award to add to the collection. Tim Maloney, manager of Electrical Engineering at Wide Bay Water Corporation, said the integration of the system differentiates it from other projects. “The Nikenbah WWTP is unique in that it is a fully integrated Schneider solution. The VSD and smart starters talk seamlessly to the Quantum PLC and Citect System using Modbus TCP,” he told PACE. “Plant redundancy includes hot standby PLCs, redundant Citect Servers, VSD and TeSys T communication rings and a site wide fibre optic ring. A single instrument vendor, Endress+Hauser, was utilised leading to reduced risk, easy procurement and system integration.” The judges said the project should be congratulated on the quality of its implementation whilst balancing environmental, cost and performance objectives.

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Phone: 1300 742 228

JULY 2011 www.pacetoday.com.au 19

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A proud sponsor of the “Young Achiever of the Year“ award.

NHP is a strong believer of investing in the future and nurturing home grown talent by providing our brightest stars with the tools and experience to be the best they can be. This is why NHP is a committed sponsor of the “Young Achiever of the Year“ award.

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PACE ZENITH AWARDS 2011 WINNER

Young Achiever Award WINNER

Brad Shaw Serck Controls Starting at as a graduate engineer in 2006, Brad Shaw progressed through the company and, at 26, is now a senior systems engineer at Serck Controls Telemetry Competency Centre (TCC). Bruce Mitchell, Industry Development Manager, TCC is all praise for Shaw. “He demonstrated the willingness and commitment to learn that marked him as one to watch. His ability to relate to the end user and foster a productive partnership with the client has reaped benefits in system design that in general exceed the project specifications. He has a clear focus on getting the job done but working within the constraints of the overall project budget.” Throughout the

GWMWater Alliance project, Shaw’s leadership and input was integral to its success, both in a financial capacity and overall solution basis. “Our successful partnership with GWMWater continues on after the initial Alliance goals were met, in no small part due to Brad and his team,” says Mitchell. When asked about his win, Shaw expressed surprise and honour at being awarded. He attributed his win to the opportunities provided by Serck Controls for career progression. “I guess this really recognises the rapid growth from when I graduated, and when I started as a graduate, and then to where I am today as a senior engineer, and my involvement in the company.”

WINNER: Serck Controls’ Brad Shaw (R) receives the Zenith Award from Young Achiever category sponsor Murray Quinn, Business Development Manager – Commercial Sector, NHP.

JULY 2011 www.pacetoday.com.au 21

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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

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PACE ZENITH AWARDS 2011 WINNER

Oil, Gas and Hydrocarbons WINNER

Apex Optimisation and Woodside Energy Karratha Gas Plant Karratha, Western Australia Apex Optimisation and Woodside Energy's revamp and implementation of the Advanced Process Control (APC) at Karratha Gas Plant has won the Oil, Gas and Hydrocarbons award of the year. Woodside approached Apex Optimisation early in 2010 to assist with a revamp of the existing APC on LNG Train 4 (LNG4) and the implementation of a new APC on LNG Train 5 (LNG5). In March 2010, after a functional design specification was completed, the project started. In May 2010, the revamped LNG4 APC was commissioned, with the LNG5 APC following in September 2010. The project was successfully concluded with a Site Acceptance Test in October 2010. APC and specifically Multivariable Predictive Control (MPC) have become well established in the hydrocarbon processing industries. APC software enables more efficient operation of existing hardware assets, making control easier for the operator, and helping maximise efficiency on LNG production trains. The Woodside operated Karratha Gas Plant (KGP) has had over a decade of history with the use of APC with an evolving plant context delivering ongoing APC development opportunities. A continual focus on innovation and design evolution in order to further improve APC benefits distinguishes the site as a mature APC user. The execution of the project was very challenging due to a range of factors because the team pursued a design evolution which widened the scope of the APC significantly beyond the original LNG4 APC implementation with additional handles, limits and configuration challenges. Additionally, the size of the new applications, with each having more than 20 manipulated variables managing in excess of 60 controlled variables, meant some complex interactions had to be modelled. The non-linear portions of the process required the team to

approach the problem with innovative use of transforms, gain scheduling and automatic logic. They had to use dynamic simulation extensively to develop the gain scheduling relationships. As use of the LNG4 APC had lapsed a year prior to the project, there were no APCs operational on this particular DCS panel and the operators had to be trained in the control technology. Mechanical modifications to the LNG5 train during the project meant project engineers had to be flexible in adapting to the changing needs while maintaining an aggressive project schedule. These challenges were overcome through good teamwork amongst the joint project team and excellent operator involvement. Close operator involvement was critical to the project success as this fostered operator ownership of the project, as well as helping to ensure that each process control improvement implemented was intuitive for the operators and appropriate for the widest range of process conditions. To ensure that the changes to the process control systems conformed to safety requirements, the designers included constraint variables which allow the desired operating envelope to be specified such that important DCS alarm and safety limits are explicitly honoured by the APC. The designers also applied tuning to cater for the specific process needs with regard to speed of response required for different constraint violations. Finally, automatic logic monitors the status of specific equipment trip signals and, when detected, puts the control system into a safe state to allow the operator to manage the process. The health of variables critical for the APC operation is continuously monitored with control returned to the operator if any become unavailable. The end result is an APC application with safe guards to ensure its use is appropriate and users who are clear on what the APC can and cannot do.

WINNER: (L-R) Category sponsor Dirk Kuiper, General Manager, AMS with Paul Kjellgren, Senior Process Control Engineer, Woodside Energy and Andrew Taylor, Principal Consultant, Apex Optimisation.

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Whether you build it... or move it Global competition. Higher costs. Increasingly stringent environmental standards. To meet your challenges you need to increase throughput and efficiency while minimising manufacturing costs, maintaining high reliability; within tight deadlines. Rockwell Automation offer you a range of solutions which can improve your operation and gives you a competitive advantage. For further information visit www.RockwellAutomation.com.au www.RockwellAutomation.co.nz

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PACE ZENITH AWARDS 2011 WINNER

Transport, Power & Infrastructure WINNER

Hero Engineering DiCOM Project Development Perth, Western Australia AnaeCo designs and operates Alternative Waste Technology (AWT) plants to process Municipal waste to produce saleable compost, recyclables and energy. Redirection of waste from landfill is processed using the DiCOM bioconversion process developed and patented by AnaeCo. The company had to demonstrate the DiCOM process as a viable AWT, requiring electrical and control systems for the demonstration facility and later the commercial scale plant. The performance trials received independent validation of the DiCOM process with regard to product quality, effluent control, demonstrated plant safe operation and robust

engineering processes. According to Sloan Thompson, East Coast Business Manager, Hero Engineering, the greatest challenge was the scope of the project. “We have been working on this project for some years already, with our partner AnaeCo,” Thompson said. “We’ve been developing all sorts of process control, safety systems and electrical solutions. We’ve progressed from pilot projects and demonstrations. “We’ve gone commercial and are transforming waste into energy and compost. We’ve been keeping in mind the safety engineering applications of system management and functionality, and bearing in mind all the process controls throughout the whole transformation.” The judges said the project was well engineered and well-managed.

WINNER: Sloan Thompson, East Coast Business Manager, Hero Engineering receives the award from category sponsor Geoffrey Irvine, Rockwell Automation – Industry Manager, South Pacific.

stralian Customer Service Centre

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w www.ia.omron.com JULY 2011 www.pacetoday.com.au 25

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Cool 50 floors without cooking the planet.

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PACE ZENITH AWARDS 2011 WINNER

Lifetime Achievement Award WINNER

WINNER: Mario Dona (C) of Santos receives the Lifetime Achievement Award from category sponsors ABB Australia: Alex Jukes (L), Low Voltage Products Business Manager and Adrian Heaton (R), National Marketing Manager – Discrete Automation & Motion.

Dedicated local engineering team High quality brands and services Industrial and commercial PC products Concept to finished product custom solutions Windows embedded certified partner Broad range of supporting industrial products Many items in stock in Australia and New Zealand

Mario Dona Santos Ltd Mario Dona’s 35 years experience in design, commissioning and operations of electrical, instrumentation and process control systems has seen him win the inaugural Lifetime Achievement Zenith Award of the year. Like many other engineers, Dona exhibited quiet humility when told of his win. “I didn’t expect to win,” he told PACE. “There are certainly other lifetime achievers who come well before me.” Currently he works as a principal engineer in Power Controls at Santos, and has been working with the company for 28 years. Dona is responsible for provision of independent Power & Controls Engineering services, to ensure appropriate and managed engineering and workflow standards for creation and operation assets are set. He represents Santos on national and international standards, industry and professional organisations, management of major incident investigations and mentors staff. He has added value to Santos by commissioning major plant control systems with long term stability and minor rework. This experience was used in later years when the plant control systems were upgraded and the plant had to be rebuilt due to fire damage. Dona has contributed to the wider community by participating in the Standards Australia IT6006-2 Industrial Process Control and Measurement IEC/AS 16508 & 16511 Functional Safety. Throughout the years, Dona has had a pivotal role in many major projects, these include providing technical guidance and engineering approval to progress and close out of the Moomba Plant fire remediation project. Specific tasks included the participation of HAZOP, coordination of CHAZOP, material substitution approval. By management of internal and external resources, he developed 62 power and controls standards within two years. He also rolled out standards via discipline engineering networks held every quarter. Dona actively managed discipline network content in terms of content, presenters, and attendees which included regulators, Santos engineering and maintenance, consultants and service providers. He is a member of several associations including; Association of Professional Engineers, Scientists & Managers Australia, IICA. For ITACS (Internal Testing and Certification Services), Dona is on the appeals committee dealing with certification issues of Hazardous Area Electrical equipment.

Rugged Handheld PDA

JULY 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.

Portable measurement The portable DEWE-3020 claims to be the smallest, rugged “all-inone” measurement system for galvanically isolated amplifiers. The portable DEWE-3020 includes a built-in touch-screen display, high isolation signal inputs, high sampling rates – up to 1 MS/s, up to 24 bit resolution, and a data throughput of 70 MB/s. The DEWE-3020 can be powered from AC or DC, or use it completely independently from external power with the hot-swappable battery power supply option. Analogue, digital, CAN-bus, GPS, video data and counter are synchronised during recording and guarantee qualitative and efficient data processing. The software DEWESoft enables synchronised data acquisition and analysis from different signal sources. The Intel Core 2 Duo processor supports online mathematical functions, displaying data on different screens during measurement. In analyse mode, the mathematical functions can be applied to previously acquired channels, and simple reports can be generated. Results are shown online on the 15.4” TFT touch-screen display. Metromatics 07 3868 4255 www.metromatics.com.au

Distributed and control cabinet inverters NORD Drivesystems is supplying PROFINET modules for the integration of frequency inverters into PROFINET environments. In the second quarter of 2011, NORD introduced new modular units for cabinet-mounted SK 500E inverters while a version for distributed SK 200E-type inverters will follow in the fourth quarter. With no need for repeaters or additional master interfaces, the newest PROFINET module from NORD cost-efficiently connects a large

number of inverters to a single bus line. The technology box supports real-time data transfer and features an integrated Industrial Ethernet switch, an integrated web server, and a PROFINET status display. The bus module for distributed control can be mounted either directly on the inverter’s interface unit or separately from the inverter. NORD Drivesystems AU 1300 00 6673 www.nord.com.au

Humidity and temperature measurement The Vaisala INTERCAP Humidity and Temperature Transmitter Series HMW80 offers both combined relative humidity and temperature measurement, as well as temperature-only measurement for temperature control applications. Ready to use out of the box, the HMW80 requires no pre-configuration or adjustment, and is easy to install thanks to its simple twopiece construction: just complete the wiring to the terminal block on the bottom of the unit, then snap on the lid of the electronics enclosure to complete the installation. The HMW80’s enclosure is made of UL V0-approved materials and is IP30 protected. The 28 www.pacetoday.com.au JULY 2011

new design in signal white (RAL9003) colour, blends in well on most modern office walls. The high power output required by the measurement signals often distorts temperature and relative humidity measurements in wall sensors. This self-heating increases the temperature reading and decreases the humidity reading. This problem has been minimised in the HMW80 by using thermal modelling and testing during the design phase. Vaisala 03 9815 6700 www.vaisala.com/HMW80

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

SensaGuard benefits from RFID and distribution The Allen-Bradley Guardmaster SensaGuard range delivers a cost-effective, machine guarding solution for industry. The units provide secure safety switching, diagnostics and monitoring in one compact package. Combining the cutting-edge technology of RFID coding with a M23 Safety Distribution block, SensaGuard simplifies the integration of multiple sensors. The latest in RFID coding provides an additional level of security, allowing a SensaGuard switch and actuator to be paired with a specific code. This enhances safety by reducing the possibility of other actuators being used to bypass the switch. The switch is paired with an actuator on initial powerup. If some flexibility is required, the switch can be re-paired to another actuator up to eight times. After the 8th time, it is locked to the last-paired actuator. At anytime during the pairing process, the switch can be locked to a specific actuator permanently. Rockwell Automation 03 9896 0300 www.rockwellautomation.com.au

Power Analyser compliant with new IEC standards The Hioki PW3198 Power Quality Analyser is a Cat IV (600V) instrument capable of harmonic and inter harmonic measurements to the 50th and 49.5th orders (including power harmonics) respectively (including phase angles) for both voltage, current; voltage and current unbalance measurement, as well as K-factor measurement useful in assessing transformer loading. Inrush current and transient over-voltage impulses (to 6 kV), voltage swell and dip as well as flicker measurement are part of the suite of measurement protocols.

The PW3198 is compliant with the latest IEC requirements, i.e.: IEC 61000-4-30 Edition 2, Class A standard thus making the instrument suitable for power line analysis acceptable to distribution authorities. It is a four-channel instrument making it suitable for threephase 3- and 4-wire reticulation as well as single and two-phase systems. Power Parameters 1800 623 350 power@parameters.com.au

National Instruments extends CompactRIO Platform National Instruments has released the NI cRIO-9075 and cRIO9076 integrated chassis and controllers, which lower the cost of the NI CompactRIO platform for embedded control and monitoring applications. CompactRIO is powered by reconfigurable I/O (RIO) and NI LabVIEW FPGA technologies and combines an open embedded architecture with a small footprint, extreme ruggedness and a wide breadth of analogue, digital, motion and communication I/O modules. The new integrated systems combine an industrial 400 MHz Freescale real-time processor and four-slot chassis with an embedded, reconfigurable Xilinx Spartan-6 FPGA. National Instruments 1800 300 800 www.ni.com/compactrio

Piglet is a Digital IP Rapid Deployment Camera The Madison Technologies ‘Piglet’ is a Rapid Deployment Camera complete with integrated battery power supply and optional 3G and/or WiFi communications. Intended for use in areas where mains power is not available or where camera monitoring is only temporarily required, the ‘Piglet’ is designed to be installed quickly and easily without requiring any fixed cabling infrastructure. Housed in a robust IP65 lockable enclosure, the Piglet can be mounted horizontally or pole mounted. The Piglet Rapid Deployment Camera can record directly to an internal SD card storage up to 16 GB, or alternatively

transmit images wirelessly via optional integrated 3G and/or Wi-Fi. The optional integrated WiFi can be turned on/off remotely via key fob to conserve battery life when not in use and enables footage to be periodically uploaded to any 802.11WiFi enabled device. The high resolution Mobotix digital IP camera is available with either an optimised Day (colour) or Night (black and white) image sensor and has a range of interchangeable lenses, (wide angle and telephoto). Madison Technologies 1800 66 99 99 www.madisontech.com.au/industrial-itc JULY 2011 www.pacetoday.com.au 29

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EVENTS & EDUCATION

WHAT’S ON

REVIEW

Inaco Technology Tour 21 July 2011, Newcastle www.inaco.com.au / 02 4968 2888 IICA Technology Expo 27 July 2011, Gladstone www.iica.org.au IICA/ISA (IC30C1) Introduction to SCADA Systems Integration 27 July 2011, Gladstone www.iica.org.au IICA/ISA (EI10C) Industrial Flow Measurement Overview 28 July 2011, Gladstone www.iica.org.au Troubleshoot AC Variable Speed Drives 2-3 August 2011, Brisbane trainingaus@ra.rockwell.com QLD Gas Conference and Exhibition 16 August 2011, Brisbane www.jktech.com.au

For daily updates visit www.pacetoday.com.au

Waste-to-Energy: Technologies and Project Implementation ‘Waste-to-Energy, 2nd Edition Technologies and Project Implementation’ By Marc J. Rogoff & Francois Screve Elsevier $175.95 This book covers in detail programs and technologies for converting traditionally landfilled solid wastes into energy through waste-toenergy projects. Modern waste-to-energy plants are being built around the world to reduce the levels of solid waste going into landfills and contribute to renewable energy and carbon reduction.

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The latest technologies have reduced the pollution levels seen from early waste incineration plants by over 99 per cent. The book provides an insight into the different approaches taken to planning and implementation.

‘Waste: A Handbook for Management’ Edited By Trevor Letcher & Daniel Vallero Elsevier $124.95 The book covers: A history of waste management; Green engineering and sustainable design aspects of waste management; Waste regulations; Waste collection; Mine waste: A brief overview of origins, Quantities and methods of storage; Metal waste; Radioactive waste management; Municipal waste management; Waste water: Reuse of oriented wastewater - low - and high-

tech approaches for urban areas; Recovered paper; Glass waste; Textile waste; Chemicals in waste: household hazardous waste; Reusing non-hazardous industrial waste; Thermal waste Treatment; Plastic solid waste and thermo-chemical treatment.

You could win one of these books by answering the following question: On which page of this magazine will you find “AS/NZS 3598:2000” mentioned? Email your answer to kevin.gomez@reedbusiness.com.au

Both books are available direct from Elsevier Australia Customer Service, 1800 263 951 or customerserviceau@elsevier.com

IICA NEWS & VIEWS

Hurdles in providing much-needed training Stand-alone qualifications in Instrumentation and Control Systems needed, writes Brett Simpson. THE Institute of Instrumentation Control and Automation (IICA) is a Federated body comprising Branches in every Australian State. The Chairpersons of those Branches form the Federal Council, which is the overarching decision-making body for strategic and advocacy policies on behalf of Members of the IICA. I’d like to look at three current examples of those policies. The IICA Federal Council sees working to raise the importance of Instrumentation and Control Systems, for example, as a separate discipline within Universities and TAFE sectors of paramount importance. A majority of Universities and TAFEs still do not offer such stand-alone quali30 www.pacetoday.com.au JULY 2011

There is very different treatment for graduates of dual-trade qualifications.

fications. Likewise, it is totally unacceptable that within the TAFE sectors, there is what can only be described as ‘very different treatment’ for graduates of dual-trade qualifications. For example, if a qualified electrician chooses to do an approved electronics course, the Federal Government (DEEWA), recognises electronics-electrical as a new jobs outcome – the person is recognised as an electronics

technician with appropriate financial incentives on this basis. Contrast that with the same qualified electrician who chooses the electricalinstrumentation dual-trade course. The Federal Government does not recognise this qualification as a new jobs outcome, i.e. as an instrumentation technician, but deems it to be only an electrical jobs outcome! There is clearly an imbalance here that needs addressing. Our third example involves the aerospace maintenance sector. The IICA has teamed up with the RMIT University and with the Australian Association of Aviation and Aerospace Industries (AAAAI) to address and provide practical assistance to manufacturers’ concerns about compliance

with mandatory International Standards. The problems are the lack of proper understanding of the required International Standards and regulatory systems for instrumentation and calibration within sections of the aerospace maintenance industry-civil and defence. The goal we are all working on is to devise appropriate CASA and Defence approved training courses, together with an on-line Registration System. The Registration System will list companies and individuals who will have completed the training courses or can demonstrate equivalent competencies. [Brett Simpson is IICA Federal President.] www.iica.org.au

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AUMA – world leader in electric actuator technology for power plants When you need electric valve actuators you need reliable, innovative, flexible solutions from a global leader committed to regional support. By choosing AUMA you can relax. A unique modular product design with interchangeable parts backed by expert local service will give you an adaptable advantage. More reasons to choose AUMA: ■

Compatibility with a wide range of DCS systems

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Solutions for high and low pressure valves

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A unique modular design with interchangeable parts

field-bus interfaces

BARRON GJM PTY LTD

78 Dickson Avenue, Artarmon NSW 2064 Ph: 02 9436 1088; Fax: 02 9439 3413; info@barron.com.au

The Actuator Specialist