PACE - Process & Control Engineering - June 2012 by Prime Creative Media

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JUNE 2012

VOL.65 NO.5

Safety Management There is no one-sizefits-all solution to the safety problem. Viewpoint 12

Communications Interface FDT 2.0 technology provides flexibility to create new software and tools.

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Alarm overload? Regain control with Schneider Electric Alarm management solutions maximise system efficiency, reduce risk and provide significant time and cost savings. Many plants experience huge numbers of alarms on a daily basis. Operators suffer from alarm overload - too many transient or ineffective alarms with little or no context or defined response. This leads to business risk in the form of potential production loss, plant damage, or personal injury.

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Consulting Services Whether you are a large or small company, Schneider Electric consultants leverage their extensive industry experience to provide customised solutions for alarm management systems.

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For more information, download our free whitepaper “Alarm Management Processes: Putting you back in control”. Visit www.sereply.com Key Code 52572K

© 2012 Schneider Electric. All Rights Reserved. Schneider Electric and Make the most of your energy are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. s 78 Waterloo Road, Macquarie Park, NSW 2113 AUSTRALIA s www.schneider-electric.com.au s 1300 369 233

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CONTENTS

IN THIS ISSUE 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 Associate Publisher: Martin Sinclair Email: martin.sinclair@reedbusiness.com.au

Editor: Kevin Gomez Tel: (02) 9422 2976 Fax: (02) 9422 2722 Email: kevin.gomez@reedbusiness.com.au Deputy Editor: Isaac Leung Tel: (02) 9422 2956 Email: isaac.leung@reedbusiness.com.au Group Sales Manager: Tim Richards Tel: (02) 9422 2818 Mobile: 0420 550 799 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 Graphic Designer: Justine Dunn Email: justine.dunn@reedbusiness.com.au Production Co-ordinator: Tracy Engle Tel: (02) 9422 2707 Fax: (02) 9422 2722 Email: tracy.engle@reedbusiness.com.au

28 Industry News 6

Teamcenter 9 New version adds an integrated systems engineering solution and tightens integration. Viewpoint 10

Printed by: GEON 20 Baker Street, Banksmeadow NSW 2019 Tel: (02) 8333 6555 SUBSCRIPTION: $99 pa incl GST OVERSEAS SUBSCRIPTIONS: NZ: $A109 pa & OS: $A119 pa

Manufacturing under threat It is clear that the security threats targeting manufacturing businesses are growing in frequency and sophistication.

CUSTOMER SERVICE: 1300 360 126

Conversation 11

Trends in instrumentation Frank Hils, Director of Projects & Solutions, Endress+Hauser shares his views on local and global industry trends. Energy 15

Efficiency improvements By following a four-step process users can do more with less while achieving energy savings.

PACE Zenith Awards 21

Finalists revealed After carefully evaluating the large number of submissions the judges reveal the finalists. IICA Corner 30

Make a difference After Education and Networking the IICA’s greatest challenge is providing effective leadership in benchmarking.

ON THE COVER AA P DC _ E P .A J CU EN OE M1 R2 J .U P NG _ 0 1 0 2 1 _ .1 p . d p fd f P a Pg a e g e 1 1 2 1 /7 0 / 5 0 /5 1 / 2 1 ,2 , 4 :2 5 : 5 4 8 PM PM

JUNE 2012

VOL.65 NO.5

Safety Management There is no one-sizefits-all solution to the safety problem.

Viewpoint 12

Communications Interface FDT 2.0 technology provides flexibility to create new software and tools. Special Report 22

OFFICIAL MAGAZINE OF: Average Net Distribution 6,849

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The E5CC/E5EC series will save you time and effort in set-up and operation, while enabling faster and more accurate monitoring/control of your process. The large, high-contrast, white LCD display contributes to the exceptional clarity and therefore readability of the E5CC/E5EC series. The display can be read unambiguously from view1 greater 4 / 0 5distances / 1 2 , and 5 from : 1 8much P wider M ing angles than normal.

Coupled with the auto-tuning algorithms, which greatly reduce set-up and commissioning time, Omron’s CX-Thermo support software has been specially developed for use with the E5CC/E5EC series. This enables faster parameter setup, easier device adjustment and simpler maintenance. Omron Electronics 1300 766 766 www.omron.com.au

Power & Energy Management Solutions to meet your specific requirements Solutions designed to provide high-functionality and measurable payback for your system investment. www.rockwellautomation.com.au

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10-May-12 10:17:18 AM JUNE 2012 www.pacetoday.com.au 3

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COMMENT

EDITOR’S MESSAGE

Barometer of industry’s health Kevin Gomez Editor

Next Issue

• Energy Management • Process Control in Mining • Safety Systems • PACE Zenith Awards 2012: Winners

DURING last month’s National Manufacturing Week, I had the opportunity to co-chair a round table for a select gathering of industry leaders. The event offered me a rare insight into the many challenges that our manufacturers face. There are the obvious hurdles that make the news, ranging from labour woes to the high dollar. It certainly isn’t easy being a manufacturer in the current climate, but numerous companies are battling on. A few, like Melbourne-based ANCA Motion, are even thriving and boosting exports. While mining is credited with keeping us out of a reces-

sion, a strong manufacturing sector is essential for Australia to retain its engineering skills – key competencies that are very difficult to acquire, once lost. The CSIRO’s Future Manufacturing Flagship is doing some innovative work in thinking about the big picture. The Flagship team believes the boundaries are blurring between manufacturing and service as clients seek solutions, not just service. A manufacturing opportunity that Australia can seize is the movement away from mass production to mass customisation. With the emergence of cost-effective additive manufacturing technologies, only

creativity will limit the ability to deliver unique solutions. An opportunity exists, perhaps, for us to develop and use advanced process technologies which enable more flexible production and more efficient processing. Such a scalable production system will reduce the requirements for capital intensive infrastructure. There are already transformative technologies being developed in Australia such as fire resistant coatings, ceramifiable plastic coatings, flexible integrated energy devices and super capacitor batteries. Economic theory states that companies facing competitive pressure are more likely

to innovate and subsequently, companies that innovate are more likely to be productive. A concern raised at the round table event was the health of the local industry. Have pressures, policies and politics weakened us to such an extent that we will find it difficult to innovate and be more productive? Is the theory valid only if there is a certain level of ‘industry health’? There are more questions than answers but ones that must be examined as the growth of our process control and automation industry is closely intertwined with the existence of manufacturing. kevin.gomez@reedbusiness.com.au

MANUFACTURING

Future manufacturing is happening here and now By JIM PINTO

Several revolutionary technologies are and “print” it. The old concepts of THE April 21 2012 edition of converging in this decade: new materials, “economies of scale” won’t matter any The Economist has an important digital and nanoscale manufacturing, more. Everything in the factories of the special report: “The Third Industrial advanced robotics, 3D printing, and a future will be run by smart software. As Revolution”. Here is a summary. wide variety of web-based services. The manufacturing goes digital, it will allow The first industrial revolution began third industrial revolution is emerging. things to be made economically in much in Britain in the late 18th century, with Old manufacturing is the assembly smaller numbers, with more flexibly and the mechanisation of textiles, elimiof mass-produced parts. Today, digitminimal labour. Designs will be “crowdnating laborious hand weaving. The ally designed products can be “printed”, sourced” – sent out anywhere in the second industrial revolution was born in creating solid objects by building up world to the people with requisite skills. the early 20th century when Henry Ford successive layers of specified materials. As the number of people directly A D _ Pmass A Cproduction E M E T Awith P Rthe _ 1 2 . p Within df P g e decade, 4 2anyone 0 / 0will 3 / be1 2 , employed 5 : 1 1in manufacturing PM developed thea next declines, the moving production line. able to simply download a digital design cost of labour as a proportion of the total

cost of production will reduce drastically. This will motivate manufacturers to move work back to advanced countries. Large manufacturers will lose their dominance because small companies and individual entrepreneurs will be able to compete. Communities offering 3D printing and other production services are already coming online in a new phenomenon called social manufacturing. The wheel of industrialisation is coming full circle. Jim@JimPinto.com

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Call Wonderware Australia on 1300 138 825 or visit our website www.wonderware.com.au 4 www.pacetoday.com.au June 2012

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NEWS ANALYSIS

SNAPSHOT

Siemens PLm Software introduces Teamcenter 9 By Kevin Gomez n THe town best known for China’s famed Tsingtao beer, Siemens PLm Software unleashed it’s own powerful brew Teamcenter 9. This most recent release, unveiled in Qingdao, is said to deliver new solutions and enhancements across the portfolio in support of the company’s HD-PLm vision. Teamcenter 9 adds an integrated systems engineering solution and tightens the integration across the unified architecture so companies can make smarter decisions with better visibility into the impact of those decisions. enhancements across the entire Teamcenter portfolio improve productivity so companies can get to market faster, while reducing total cost of ownership. “To face the challenge of increasing

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LAUNCH: Siemens Industry Software managers K C Yee (L) and Rohit Tangri at the Teamcenter 9 launch in China. globalisation of the enterprise and the ever-growing complexity of products, our customers require a more intelligent PLm system that provides the right information to the right person at the right time,” said eric Sterling, Senior vice President, General manager, Lifecycle Collaboration Software, Siemens PLm Software. “Teamcenter 9 continues to build on the unified architecture with a more integrated approach to connecting the information generated by teams across the extended enterprise, while giving them a more personalised and productive user experience.” “We have teams that create industry-

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specific best practices drawn from certain customers and this is shared with our users around the world,” said Rohit Tangri, Head, Teamcenter Product Management & Marketing, Siemens Product Lifecycle Managament Software. “We are moving towards industry templates and less customisation,” he told PACE. “The SME market is important to us,” explains K C Yee, Senior VP and Managing Director Asia Pacific, Siemens Industry Software. K C believes that the “manufacturing heroes of the future” will come from Asia. “Collaboration is a big challenge for SMEs as they are often suppliers of subassemblies to major manufacturers.” An area of interest for Australia is the possibility of employing PLM software in mining, especially with regard to sustainability. Tangri reckons that customers of mining companies, rather than mining companies themselves, will lead the charge on this front. on the 3D “There A D _ PisAincreasing C E A Minterest S J U in N _deter1 1 . p VISUAL: df P aAguser e views 1 6a /colour 0 5 /coded 1 1 ,graphical 3 : 5report 5 Pdirectly M product model. mining the environmental impact a

piece of equipment has as it moves from cradle to gate and from cradle to grave,” explains Tangri. Highlights of Teamcenter 9 are: o It provides a fully-integrated approach to systems engineering and requirements management. o The enhanced integration of content management allows product documentation to be created in parallel with the design process. This ensures that changes are communicated as they occur and their impact can drive documentation more efficiently. o It integrates the service scheduling and execution management solutions, enabling companies to more effectively control cost by defining and efficiently scheduling service orders and tasks. o It makes it easy to tailor the user experience with stylesheets that can streamline processes regardless of whether they use the traditional Teamcenter rich client (application) or thin client (web). www.siemens.com/plm

June 2012 www.pacetoday.com.au 7

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NEWS

MOTORS & DRIVES

ABB expands motor services business ABB will acquire the business of Bob White Electrix and L.E. Jarvis to broaden its motor and generator repair and service business in Australia. Bob White Electrix has been established in the Australian marketplace since 1946. The company has in-house specialist coil manufacturing, large motor and generator repairs and a high speed-balancing pit built to accommodate rotors up to 85 tons. Over the years, Bob White Electrix has built a reputation in the field of generator and motor repairs, including very large machines of up to 230 tons. L.E. Jarvis has been operating as a business in Perth since 1967. Since that time, they have built a reputation as a quality service company specialising in rewind,

repair, maintenance and overhaul of industrial motors and generators. With two workshops in Victoria and one in Western Australia, this acquisition complements ABB’s motor sales portfolio and enables ABB to service customers across all states of Australia. ABB currently has a service workshop in Brisbane. “It will enable our current field service team to draw on the experience of nearly 100 additional resources and will establish ABB as a leader in generator and motor repairs,” said Axel Kuhr, Country Manager of ABB Australia. To ensure continuity for customers, ABB will retain all existing staff from its three current sites. www.abbaustralia.com.au

ACQUISITION: ABB broadens its motor and generator repair and service business in Australia.

RESEARCH

Australian solar cell breaks 20 percent barrier Australian solar research has produced Pluto technology, as it is patented, new photovoltaic solar cells that recently was developed by Professors Martin broke the 20% barrier for efficiency in Green and Stuart Wenham at the ARC capturing the sun’s energy, the highest Photovoltaics Centre for Excellence in ever efficiency for a low-cost commercial close collaboration with the world’s largest silicon solar cell. solar cell manufacturer, Suntech-Power. LOW COST: Sketch of the Pluto cell. The solar cells reached a production “We recently broke through the 20 capacity last year of 0.5 gigawatts, worth per cent target for solar cell efficiency, more than US$1 billion a year. This is which many experts thought was imposenough to power 300,000 average homes sible and we’ve significantly lowered the of New South Wales. that typically have eight solar panels on costs compared to other technologies,” Professor Green believes this success AD_ PACET URJ UN_ 1 2 . p d f Pa ge 1 8 / 5 / 1 2 , 1 0 : 5 6 AM them for at least 25 years. says Professor Green from the University was earned through deep collaboration

with Australian company SuntechPower: “We brought our photovoltaic knowhow together with their manufacturing expertise, which used new tools and processes to create solar cells ten times the size of our lab-scale devices.” Suntech-Power’s expertise was important for lowering the costs of the cells by using cheaper processing methods, like laser patterning, and replacing expensive silver and titanium parts. www.pv.unsw.edu.au

What are the crucial

considerations to

determine the correct level detection sensor?

TU-1288 53.0612.03 TURCKMan Ad_Horiz_Process&ControlEng.au.indd 1 8 www.pacetoday.com.au June 2012

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OPINION

SECURITY

Manufacturing under threat Australia’s manufacturing sector is a target for cybercriminals, writes Keith Buckley.

HE manufacturing industry manufacturing industry between 2009 into disclosing confidential information is an important sector for and 2010. In fact, since 2008, the or downloading malware and is often the economy employing manufacturing sector has been the target used by cybercriminals to bypass an one million Australians and of more web attacks than any other organisation’s security systems. accounting for more than 10 percent industrial sector in Australia. Social engineering attacks are of the country’s economic output. This With cybercriminals increasing their becoming more advanced and trickier sector is thus an obvious target for focus on this industry, it is vital for to spot. For example, cybercriminals use cybercriminals as demonstrated by a manufacturing companies to understand news events as a way to spread malware. recent attack called Nitro which targeted and tackle the security issues they are Recently the death of Muammar more than 48 organisations involved facing. The first step in this process Gadhafi was the subject of spam emails in the manufacture of chemicals and comes from understanding where which encouraged recipients to click on advanced materials. vulnerabilities lie. a malicious link. Users who fell for this Nitro appeared only in recent The internet threat landscape is scam at work downloaded malware to months but cybercriminals targeting the evolving rapidly and cybercriminals are business computers, enabling cybercrimmanufacturing sector is nothing new. finding new ways to attack corporate inals to access the corporate network. According to a survey conducted by data by targeting employees via social Email scams are also a common Symantec.cloud, A D _ P A Cthere E P was R Y aF60 E percent B _ 1 2 . pengineering df P aattacks. g e ‘Social 1 9 engineering’ / 0 1 / 1 2 , tactic 5 : to 0 4encourage P M employees to downincrease in targeted attacks against the is the act of manipulating employees load malware. For example, the recent Nitro attacks were spread via targeted emails to employees within private manufacturing firms. Cybercriminals researched desired targets, and then sent emails to a handful of employees at each relevant firm. These emails UE Solid state pressure switches often purported to be meeting invitaImprove reliability with UE electronic pressure and temperature tions from established business partners, Switches. Available for hazardous locations the tricking recipients into opening an One Series provides precise control and attachment and enabling malware to features Plugged Port detection. enter the business network. Once the • Solid State design with no organisation was infiltrated, Nitro was moving parts able to collect intellectual property such • Field programmable for set as design documents, formulas and point and deadband control manufacturing processes. In addition to social engineering • 2-Wire design is a drop-in replacement for threats, mobile devices often create a mechanical switches point of vulnerability. The use of mobile devices is on the rise in the manufac• IAW®(I am working) self diagnostics turing industry as many employees work across multiple sites or are often on • Pressure ranges to 4500 psi/Temp. the road. These employees tend to use ranges to 1000°F personal devices such as tablets or smartphones to access corporate data. While the use of mobile devices improves productivity in the workplace, a growing concern is undoubtedly the security risks associated with their use. Remote workers accessing the Internet from outside of the company network or Pryde Measurement Pty Ltd VPN can be more susceptible to security Ph: 1800 688 211 risks. This is because mobile devices are Melbourne | Sydney | Brisbane | Perth unlikely to have business quality security info@pryde.com.au software installed, making it easy for opportunistic hackers to access business

How do you improve?

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data. Additionally, the use of unsecured networking environments can significantly increase security risks. How can the manufacturing industry protect itself? While it is clear that the security threats targeting manufacturing businesses are growing in frequency and sophistication, there are some simple steps that these organisations can take to protect their business data. o Educate employees: Businesses in the manufacturing sector should keep employees updated on recent security threats and the risks of accessing business data through mobile devices o Avoid opening unexpected messages from unknown senders: Emails, social networking messages and text messages can be used to spread malware, phishing scams and other threats. Remind employees to use caution when opening unsolicited messages o Click with caution: Employees should not open unidentified links, chat with unknown people online or visit unfamiliar websites. It doesn’t take much for a user to be tricked into compromising a mobile device or a networked computer and enabling malware to enter the business o Use a reliable security solution: Look for a solution that does more than just prevent viruses. Advanced solutions identify programs that match the software’s database of known malware, suspicious e-mail attachments and other warning signs. These solutions can be delivered as a cloud-based service which will automatically provide the most updated threat protection possible. o Invest in the Cloud: Businesses in manufacturing should consider investing in cloud-based filtering services which stop threats at the internet or email layer, preventing them from entering the business network through networked computers or mobile devices. [Keith Buckley is Regional Director, Symantec.cloud.] www.symantec.com/en/au/

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CONVERSATION

INSTRUMENTATION

Future trends Frank Hils shares his views on local and international industry trends. By Kevin Gomez. Frank Hils, Director of Projects & Solutions, Endress+Hauser visited Australia recently. He took some time out from his busy schedule to talk to PACE about current and impending developments in the industry. Why hasn’t Profibus made much headway into Australia’s manufacturing sector? Well, I don’t know the Australian market well enough. Fieldbus technology actually started in the manufacturing industry and from there it moved into the process industry. This is from a technology perspective. The other aspect to consider are the contenders on the systems side. Profibus was pushed by Siemens, by European manufacturers, so it’s more or less a question of who dominates a certain market. You could also turn it around and say that Profibus PA supporters did a great job in Australia, because the adoption of Profibus PA is very strong here. Do users still have concerns about wireless applications? People always have concerns if they are confronted with a new technology. You can address that in two ways. On one side, you can come up with calculations, technology, architectures, and try to remove that fear. The other approach is, to tell them, ‘when you’re afraid, step back and don’t use it.’ The first time you apply a new technology, it is a learning curve. When challenges arise, it is important that the user have a partner who takes care not just to supply the technology, but also to help them take that technology on board. In wireless for instance, we decided not to merely supply components which are WirelessHART compatible, but to also provide an entire service package. It starts with consulting, site surveys, commissioning support and performance monitoring to reduce risks. Usually, users are not afraid about the technology, but about the business impact. We recognise this and do not position ourselves merely as a supplier, but also as a partner when adopting new technologies. There are many measuring points and several instances where no measurement is possible with today’s technology. Here, wireless technology and wireless components provide a solution. There are risks and customers are looking for a vendor who will accompany them on that path. How do you see the two competing wireless standards evolving? There are always different approaches to solve a problem. Now, I need to separate my role as a representative of the HART Communication Foundation and my position as a supplier. As a member of the HART Board, I can assure you

that WirelessHART technology is absolutely applicable to the target industry, which is the process industry and the sensor and actuator world. This is where HART is positioned and what it claims as their area of responsibility. Now, as a member of Endress+Hauser, as a supplier, we listen to our customers. If there are other requirements which go beyond what HART claims as their area of responsibility, we would need to provide other technologies. For the time being, we are committed to WirelessHART with our product range. We do not have any plans currently to move into the product stage with ISA100.11a. What developments do you see in instrumentation? On the industry front, there is the tendency towards bioprocessing, miniaturisation and online diagnostics. It’s no longer just traditional process measurements, but also quality-related measurements. This has an impact on the supplier. So we are working on further extending our range, both in the volume measurements as well as in the quality or properties of liquids or solids. The analytical world is an area of strong investment. What solutions does Endress+Hauser offer in the area of energy management? We have all the necessary equipment to measure energy consumption. Then, of course, we have energy monitoring systems, so we collect all of that information and provide software in conjunction with this. But it is not just the products and the software, it’s also the integration service and the project services. Once you monitor consumption, the customer is not satisfied and also wants to optimise their energy use. Recently, we acquired a small consulting firm [Systemplan] which advises companies on ways to optimise their energy bills. It became obvious to us that the real customer need is not in monitoring, but in managing and reducing the energy bill. We position ourselves as a partner to assist companies measure their energy consumption accurately, and then offering advice on how to optimise their energy. We would never do energy consulting in isolation. The energy consulting is always an extension to the measurement and monitoring – to provide insight to the analysis. The [Systemplan] acquisition happened less than a year ago. At this time, we do not plan to launch this service in Australia. But the intention is to provide the service globally over the next three to four years. www.au.endress.com June 2012 www.pacetoday.com.au 11

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OPINION

SAFETY

Safety partners productivity

Tread carefully as there is no one-size-fits-all solution to the safety problem, writes Frank Schrever.

F SAFETY ain’t productive, it the extent of expressing a guarding hierable, isolates the hazard from us, thus ain’t safe. archy which defines the guarding types reducing the probability side of the risk This rather ungainly statement and the order in which they should be equation (risk = severity x probability) points to a profound truth in examined and employed, so far as is to a very low level regardless of the manufacturing environments: safety reasonably practicable. severity of the injury that might result if applied without reference to productivity This hierarchy is central to many we were to come into contact with that of the workplace and the operability engineering solutions for risk minimisahazard. Job done? Not quite. of the machines, plant and equipment, tion of machines, and here the law has Most machines require that we do can lead to quite dangerous outcomes got it just about right. have to have access to the dangerous regardless of the technical and legal If we can, says the law, (including parts for operation maintenance or compliance of the safety solution. the new harmonised laws now enacted cleaning. In this case, says the law, How can this be? Let’s examine this by NSW, Queensland, the Territories we must have an interlocked physical in some more detail. and the Commonwealth) we must apply guard. But how do we design the interThe law has long been exhorting a permanently fixed (welded) physical locking system so that it is guaranteed us to eliminate risk and if that is not guard. This, of course can only happen to function, so that the switch and possible, to minimise it by engineering if access is never required for operation, control system can’t fail and let us into a means. running? A D Those _ P A engineering C E O M R Jmeans U N _are1 2 _ 2 maintenance . pdf Pora cleaning. g e 1 2 1 / 0 5 / 1 machine 2 , 1 which : 0 2is still PM not described in legislation, except to A guard which is not removThe law has nothing to say about

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these things, but it does point us via the codes of practice to Australian standards, which do. And the prime standard in this regard is AS 4024.1-2006 Safety of Machinery together with its suite of technical and machine specific standards. It provides detailed guidance on how to design safety control systems which have decreasing probabilities of dangerous failure as the risk increases. So, knowing this, the job must be done now? Not quite. Is it practicable to interlock every guard that has to come off a machine for operation, maintenance or cleaning? Absolutely not. So where to from here? Well, the law quite sensibly leaves this decision to you. If you decide that it

ver.

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is not reasonably practicable to weld or This is simply because humans are and a presence sensing system will not interlock a guard, then you can now use relatively unreliable when it comes to contain those hazards even though it a guard that can only be removed with performing repetitive tasks and accimay well detect the object moments the use of tools, and the standard AS dental, occasionally deliberate departures before it strikes you 4024 supports this further by saying that from procedure are made, i.e. guards are Nevertheless, there are many the tool should not normally be available left off with the machine running. instances, for example palletising to the operator. This can of course happen even machines, where presence sensing is the There are five tests for reasonable when guards are removed infrequently; ideal solution. Goods can enter and exit practicability, defined in the OH&S act thus the sensible approach in the legal the machine freely by careful muting of (and in the harmonised act) and each hierarchy of risk control which tells us the presence sensing device. However, if one should be considered in the context to minimise risk by engineering means a human tries to enter such a machine, of that risk. Cost is at the bottom of first, before relying on human behaviour the machine shuts down, controlled that list, but can be a valid argument via administrative controls and PPE. by an AS 4024 based control system only if it can be clearly demonstrated So, are we done now? Not yet. matching the level of risk. that the cost is grossly disproportionate Physical guards may not always be Are we done? No, the most importo the risk. reasonably practicable. In these cases a tant part is still to come. Many guards are rarely removed; presence sensing system can be used. If we simply, diligently follow the for instance, the idler guards on a very These are devices like light curtains requirements described so far we could long conveyor, and if that is the case, or pressure mats which detect people be ignoring the most dangerous and an argument may be legitimately raised entering a hazardous area and shut the often subtle issue. That is, the tendency to bolt these guards only. Sadly, these machine down. of humans to want to do things quickly approaches are often applied to guards Why is a presence sensing system at and easily. A safety system which has that are removed frequently, and over the bottom of the legal guarding hiernot taken this into account can, and time people to A diligence D _ P A wains, C E R complacency O C 2 J U Ncreeps _ 1 2 . archy? p d f Simply P a because g e 1many 1 4machines / 0 5 / 1 2 frequently , 5 : 1does 9 motivate PM in and terrible injuries can result. can eject objects at very high velocity, bypass or defeat the system which is

slowing them down or making their job more difficult. They are not usually doing this with malicious intent, or to harm themselves, but with the laudable motive of maximising output. That is, production. Often, safety designers with safety only in mind, cleverly attempt to make things extraordinarily difficult to defeat (which the law also asks of us) only to find that the defeater has been even more highly motivated to find even cleverer ways to get around it. And all because the productivity and operability of the machine was not considered in the safety solution. We must have the productivity and operation of the plant we are trying to make safe, at the forefront of our thinking. There is no one-size-fits-all solution to this problem. [Frank Schrever is Principal Consultant, Machine Safety By Design.] training@msbd.com.au

EtherNet/IP ENABLING AUTOMATION CONTROL WITH I.T. INTEGRATION ON STANDARD, UNMODIFIED ETHERNET. Share secure, real time information between the manufacturing plant and the wider business enterprise. By getting real time information in valuable and understandable formats for the different people in your organisation, manufacturers can take advantage of network convergence to greatly enhance the agility of a business and provide opportunity for greater innovation. Rockwell Automation and its partner, Cisco, have been driving these developments so that you can take standard, unmodified Ethernet and do extraordinary things. See something extraordinary at: www.apac.rockwellautomation.com/ethernetip/PACEB

EIP_Pace_half-pg_may12.indd 1

10-May-12 9:46:33 AM June 2012 www.pacetoday.com.au 13

PA2255_Awards_May.pdf

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PACE ZENITH AWARDS

MELBOURNE 14 JUNE 2012 The PACE Zenith Awards recognise and reward companies that have demonstrated technological excellence and innovation.

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PACE.JUNE12.PG015.pdf

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Energy efficiency improvements By following this four-step process users are able to do more with less while at the same time achieving significant energy savings, writes Samuel Coupel.

T IS estimated that commercial buildings currently account for about 10 per cent of Australia’s greenhouse gas emissions – most of which can be attributed to electricity consumption. This figure has in part spurred the Federal Legislation for the Commercial Building Disclosure (CBD) scheme that came into effect on 1 November 2011. All sellers or lessors of office space of more than 2,000 sq metres are now required to obtain and disclose an up to date energy efficiency rating, and building owners must obtain and register a Building Energy Efficiency Certificate (BEEC) energy efficiency star rating for the building. The legislation will have an impact on engineers involved in the construction or redevelopment of large buildings. Now the CBD has been fully implemented, building owners have an imperative to understand their energy consumption and make information publicly accessible on the Building Energy Efficiency Register, and this means it is critical for engineers to understand building energy as well. Utility costs can exceed 30 per cent of a building’s overall operating expenses, so knowing when, where and how the building (or its occupants) consumes energy is vital – yet many organisations do not take the time to track and monitor their energy use.

first place. Any energy management plan needs to go beyond the initial planning and implementation stage and include a long-term strategy for monitoring and sustaining the improvements.

Sustainable improvements

Comparison methods compare the current measurement with a previous period. For building environment measurements, complexities such as the weather, changing operational hours, and building uses may cause discrepancies in data comparison, and these factors make it difficult to use this method. There are services and software available that model the building and account for these complexities, as the model must be kept accurate in order to be effective. Bill comparison is simply comparing the current bill with the previous month’s or year’s bill. This method >

Most improvements require periodic action in order to continue delivering a benefit. This can include awareness programs, lighting schedules, economisers, automated flushers, and many other activities that require attention and ongoing maintenance after the initial project completion. Unfortunately, these ‘active’ improvements can be easily derailed by inattention: they can be stopped, turned off, bypassed, corroded, or simply forgotten. All benefit gained is then lost, and the result can be worse performance than if no attempt had been made in the

Actionable measures

Successful energy management relies on having actionable measures based on real information. But top-level energy metrics are the culmination of daily operations and many decisions made by people, processes and technology. By the time a top-level issue is recognised, it can already be costly. It is important to consider what strategies deliver the information to act before a problem develops. In practice, a combination of methods will produce the information to assess and control an active improvement without becoming overly expensive. As long as the measurements are taken on a regular basis, they will show trends over time, which can be periodically reviewed to determine if the improvement is performing as intended. The measurement method that is selected depends on the level of information required. Measurement methods take the following three general forms: • Comparison • Indirect measurement • Direct measurement

SUSTAINABLE: A D _ P A C E Most A D Vimprovements J U N _ 1 2 .require p d f periodic P a gaction e 1in order 1 4 / to0 5 / 1 2 , continue delivering a benefit.

Comparison

June 2012 www.pacetoday.com.au 15

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PACE.JUNE12.PG016.pdf

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will indicate how a program is performing, but doesn’t usually deliver information about which individual measures are working. It shows overall performance of large projects or those with interrelated improvements; however, it won’t show what other effects are occurring. Comparison methods, therefore, have a number of drawbacks compared with other forms of measurement due to the variable inputs that cannot be compared or evaluated.

all the lamps multiplied by how many hours they are turned on. In this case, the only measurement needed is total current (amperage), because voltage can be assumed unchanged. If the amperage is higher than it was right after removing lamps, more lights were added or the wrong lamps were used. Control systems are capable of logging measurements over time. This requires that the device is wired to, or somehow controlled by, the control system. The system logs a time-stamped Indirect measurement measurement, which becomes available Many measures can be taken indirectly, on one or more system reports. For based on assumptions. Impractical or example, we might need to determine if expensive measurements, cost or time a scheduling strategy is still in effect. A constraints, and unknown conditions look at logged amperage readings over can contribute to the need to take time or the on/off events could give this approach. insight as to if the scheduling strategy lights and possibly exhaust fans is availIndirect measurement is effective remains in effect. able if they have been turned on because when any assumptions and measureLooking at events reported within the room is occupied. ments for a performance metric have a control system is also effective for Direct measurement little impact on the metric. Using an devices that automatically respond to an LEDAexit lights as an example, the event. If an access-control system logs D_ P ACE CONJ UN_ 1 2 . p d f P a g e 1 1 4 / 0 5 / 1 2 , Direct 5 :measures 3 1 Pshow M the performance directly without assumption. If the consumption is the total wattage of room occupancy, then runtime for the performance requirement in a critical room is to be 20°C +/- 1°C, that can be inexpensively measured and reported. There are a wide variety of manual and automated sensors for these measurements and a host of systems to record the data produced by them. Measurements can also be captured without automation, as a part of regular maintenance. Installing a power meter on a sub-circuit or component of a system gives a direct measure of that system’s performance. Power meters are devices typically installed at various points within a facility’s power distribution system. The role of power meters is simply to record how much electricity is used in a circuit, which can provide an engineer critical data about the areas within a facility that need to be addressed. Power monitoring is also effective because, in addition to metering electricity usage, these devices can also measure power quality. Poor power quality, or power that’s rife with voltage sags and swells, can have a negative effect on facility components and contribute to substandard performance and unplanned downtime. Energy management software converts the raw consumption data from power meters and monitoring system into historical data that can be studied to identify areas that require attention. 16 www.pacetoday.com.au June 2012

Sub-meters can isolate a specific area to show if a behaviour program is beneficial and should continue. Where the expected change is less than 10 per cent in each specific area, comparing bills will not be accurate. Variations in the month-to-month consumptions, billing periods and estimated bills make it impractical for use. The design and installation of sub metering products when executing a construction or redevelopment project will therefore help the facility or building manager to measure energy usage and comply with regulation and work to reduce consumption over time.

Information

Buildings are dynamic entities, with constantly changing needs and occupancy. One-time energy audits show only a snapshot of energy use, and monthly utility bills only act as a “rear-view mirror.” Busy operations staff may not have the time, tools, or training to analyse monthly/annual energy use and investigate or troubleshoot incidents, much less compile data into an easy-to-read format to share with business leaders. Because of the complexities of energy use and its large economic impact, a growing number of firms are turning to remote energy monitoring to provide the technology and know-how to guide, measure, and help manage energy costs. Using a web-based system, remote energy monitoring automatically collects energy consumption data via smart meters, data loggers, the BMS, and network controllers, or directly from an organisation’s utility provider. Information is then compiled, organised,

PACE.JUNE12.PG017.pdf

and provided in a concise format to show the building’s energy reporting, alarming, and monitoring, as well utility analysis for electricity, gas, heat, steam, oil. Monitoring can provide up-to-date information on energy use and carbon emissions so companies can identify energy conservation measures, adjust usage quickly, and reallocate savings where needed. Energy engineers can monitor a building’s energy efficiency and actively look for opportunities to further energy-saving opportunities. In addition, energy alarms can be investigated and long-term trends analysed to help sustain reduced energy consumption efforts.

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facility managers elect to address the easiest fixes first. This can include installing more energy-efficient lighting fixtures and luminaires, increasing insulation, or deploying power factor correction devices. While these passive energy efficiency tactics can translate into substantial savings, continuous energy improvement over the lifecycle of the facility and changing conditions should be the ultimate goal, which is best facilitated through automation and regulation. 3. Automate where appropriate There are automation options that create energy and cost savings that are to know later whether energy efficiency more substantial than passive measures. measures identified as part of a strategic Motors are most crucial components Best practice energy management plan are working. in the buildings. Automation technoloHere is a four step process to achieving Thus, the first step entails collecting data gies can adjust motor speed and reduce the optimal energy management system. for major energy consuming applicaenergy consumption, which can translate 1. Measure energy use tions and the most effective methods of into significant savings. Before doing anything, it’s critically accomplishing this is through an energy 4. Monitor and control important to establish an energy usage audit and metering. A strategic energy management plan baseline because it can suggest the most 2. Fix the basics helps ensure energy and cost savings effective time. Power meter A D _course P A CofEaction. D WYAdditionally, M A R _ 1 2 . p When d f they P a realise g e that 1 building-wide 1 0 / 0 1 / 1 2 , don’t 9 :erode 4 0 over AM without a baseline, there will be no way energy usage requires attention, some installations, monitoring services, energy

Energy management software converts the raw consumption data from power meters and monitoring system into historical data that can be studied to identify areas that require attention.

efficiency analysis and energy bill verification can all help achieve this. This is a tool that pulls data in real-time from each metering device, uploads to a centrally hosted online portal and delivers business intelligence to company stakeholders in addition to the facility manager.

Lifecycle approach

Real-time analysis, information gathering and tested, validated and documented system architectures are critical to streamline processes. As the need to achieve greater efficiencies across all of industry rises and pressures to reduce energy consumption become greater, the ability to access realtime contextual information to make business decisions is increasingly important. Automation as part of a wider energy management plan should be a key driver to achieve these efficiencies. [Samuel Coupel is Product Manager, Energy Management & Power Quality, Schneider Electric Australia.] www.schneider-electric.com.au

June 2012 www.pacetoday.com.au 17

PACE.JUNE12.PG018.pdf

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Defence is in the depth The Plant of the Future will take advantage of more security technologies integrated into the control systems with easy to use management and configuration tools, writes Jason Urso.

S WE consider facilities operating process control, especially those associated with critical infrastructure, we are increasingly concerned with the defence of the environment – protecting it from intrusion both from the inside and outside. We have made great strides in building this defence, and a small percentage of top tier suppliers of control systems and customers are applying best practices to this problematic area. Over the next three to five years, new and maturing technologies will be added to the portfolio of available and proven strategies for defending and protecting control system assets. To get started addressing the security challenge, organisations will benefit by implementing a security feedback loop that operates on the following premise: Threats intending to exploit vulnerabilities require counter-measures to minimise risk to assets. That’s the Threat/ Risk Assessment portion of the loop. The security feedback loop represents an on-going process. Consistency and confidence in the process is the goal. Through the process, security awareness and defence continues to evolve to meet the ever changing threats and new vulnerabilities. To support the security process, there are several areas that are relatively robust today, including: • Risk Assessments • Control Firewalls • Policies and Procedures • Antivirus • Segregated Process and Information Technology • Microsoft Patches • Locked down / Least privilege approach on Personal Computers • Network policies for squelching Denial of Service attacks • Backup/Recovery • Monitoring Security Audit Logs • Firewall Segregation One of the logical first steps in determining the exposure of a control systems environment is a Risk Assessment, 18 www.pacetoday.com.au June 2012

PLANT SECURITY: Viewed graphically the Threat/Risk Assessment portion of the loop looks something like this. providing a summary of risk areas and actionable recommendations to either remove or neutralise the risk. And as technology advancements are introduced into the control systems environment, we’re seeing requirements for increased vigilance and the application of best practices and techniques that will continue to offer increased peace of mind. Where do we go from here? With the process security foundation defined above, the next question is – what technology and process evolution can help us make a step change in security process control systems into the future? I propose four areas that will play a significant role in security improve-

ment over the next five years: • Whitelisting • Encryption • Role Based Access Control • Increased usage of Remote Security Operations Centers

Whitelisting

Why white list? Perhaps your first introduction to the “white list” approach was for email management – specifically, for eliminating spam and allowing messages you want to receive. We see it today as a way to prohibit unapproved software/applications from running on the protected system. “Good” software makes its way

onto the white list, while unauthorised software is prohibited from executing and doing whatever “bad thing” it was intended to do. Many enthusiasts believe whitelisting is a good defence against “zero day” intrusions – preventing some, but not all. Whitelisting advocates in Australia are looking at advancements in whitelisting as a way to quarantine unauthorised software upon discovery, quarantine after blocking, enhance whitelist management, and as a way to produce a file system inventory that can accelerate verification of software on a hardware platform. Regardless of the depth of initial >

AD_PACENIAJUN_12.pdf

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PACE.JUNE12.PG020.pdf

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usage in control systems, whitelisting is a technology that provides another layer of defence and will be available for process control systems.

Encryption

What technology evolution can help us make a step change in security process control systems into the future?

Almost all communication on a control system is cleartext, sometimes used synonymously with plain text. With this situation, a man-in-the-middle (MITM) attack, a form of active eavesdropping, is possible. This type of attack allows Encryption, by itself, can protect the the intruder to “fake out” its victims, confidentiality of messages, but other passing information as though it were a techniques are needed to protect the trusted endpoint, operating in a “trust integrity and authenticity of a message. the sender” scheme. For process control, we recognise A solution is to adopt encrypted the need to protect against modification communications. Encryption is the from sender and receiver end-points. process of transforming plain text, using Today, with Internet Protocol security an algorithm, to make “the message” (IPsec), we can perform end-to-end unreadable to anyone, except those authentication, allowing the protection possessing the encryption key. It is a of the message without encrypting the common method for protecting infordata. As an IPsec configuration option, mation in commercial systems and with data can be encrypted as well. wireless communication. One of the One point to be considered, however, questions is where to encrypt the data – is how A D _ P A C E C O N 2 J U N _ 1 2 . p d f some P network a g e intrusion 1 1 5 detection / 0 5 / 1 at rest or in transmission. features are implemented. For example,

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encrypting data can cripple network intrusion detection capabilities. The security strategy for the control system environment must balance the benefits and select the appropriate set of options.

Incident Detection

Intrusion Detection Systems (IDS) are applications that can include both hardware appliances and software solutions. The IDS resides on the network and is useful in detecting attempts to access the network. Once again, traditional IT organisations have used these systems for many years, and we have found them equally useful in the control systems environment. An IDS will act to alert the network administrator of intrusion attempts and record all alert information, according to parameters set by the administrator. There are network-based as well as host-based IDS’. Some control systems today are integrated with network-based IDS. However, over time we expect to 2see , a migration 1 2 : 0 8towards P Mgreater pervasiveness of this technology as well as the application of host-based IDS. IDS’ have the capability to inspect the network packets as they flow through the system. Today very few control system protocols are understood by IDS’ and we see that changing in the future as more of the protocols are defined and implemented making the IDS for control systems more effective. In addition to intrusion detection, the idea of intrusion prevention is very attractive. Intrusion Prevention Systems (IPS) are relatively new to the world of incident detection, and offer the benefit of preventing the intrusion, not just detecting an intrusion and reporting on it after it has occurred. Remote centres for network and security management help to ensure optimal performance and administration of a process control network and security infrastructure via a set of remote services. Many process control organisations today are challenged to address areas requiring specialised skills – skills that are more closely aligned with the IT organisation. While these capabilities are both valuable and necessary, focusing on business results ranks higher with in-house resources. For these reasons, many organisations will turn to a solution that provides the skills and services necessary to keep the process control network running in a secure environment. Over the coming

years, we expect to see an increased utilisation of this type of remote service.

Plant of the Future

The Plant of the Future will be compliant with IEC 62443 – which means that our industrial information technology will be compliant. IT best practices for security will increasingly be applied on process control. We will see a move toward more individual accountability. This increased individual accountability will be achieved through more role-based control and access-enforced end points instead of “in the middle” approaches. Today, change points are detected and made on the server. In the future, these change points will move closer to where the impact of the change resides – in other words, closer to the controller. For role-based access control (RBAC), a way of increasing individual accountability, we will see encryption used as a step in the right direction. We need to adopt a security mindset – based on the premise that all trust is limited. One element of that mindset is compartmentalisation in order to minimise what must be defended, minimising the increment of potential loss. Another aspect of a security mindset is Defence in Depth – one “Maginot Line” is not sufficient. Trust is an important element in our security mindset, but we must understand that unverified trust decays over time. Verification testing then becomes an important aspect – we must re-verify the basis for trust and our verification testing should not be predictable. As part of our mindset, we must assume that some personnel and equipment are compromised by “the attacker” – just another reason why a single “Maginot Line” is not enough. As we consider the next five years or so, we can see that the Plant of the Future will take advantage of more security technologies, more and more integrated into the control systems, with easy to use management and configuration tools. The security mindset will become ingrained, just as safety has become ingrained in our control systems today. Being prepared, informed, and optimistic will help to ensure continued success. It’s an evolution – not a revolution! [Jason Urso is Chief Technology Officer, Honeywell Process Solutions.] www.honeywellprocess.com

PACE.JUNE12.PG021.pdf

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PACE Zenith Awards 2012: Finalists The judges have pored over the large number of entries and the following have been selected as finalists. Automotive & Manufacturing Proudly sponsored by ifm efector

Machine Builder Proudly sponsored by B&R Automation

• ABB Australia Project: SynRM Synchronous reluctance motor • CASWA Pty Ltd Project: CASWA AccessPack • I S Systems Pty Ltd Project: Tomago Aluminium Boosted Suction system • Konecranes Project: Air Warfare Destroyer Project • Matrix Composites & Engineering Project: Composites Syntactic Manufacturing Plant • Robotic Automation P/L & Amcor Cartons P/L Project: Robotic End-of-Line Solution

• ANCA Pty Ltd Project: MX5 CNC tool and cutter grinder • CKAS Mechatronics Pty Ltd Project: CKAS “Cranky” Full Motion Wharf Crane Simulator • Fibre King Pty Ltd Project: Laminator Tray Erector • H&H Machine Tools Australia Pty Ltd Project: Ultra5 • Konecranes Project: Intelligent Crane Solution for the Steel Industry • Ryan Aerospace Pty Ltd Project: Helicrew Helicopter Simulator • SEMF Pty Ltd Project: Sante Fe Jack Up Barge – Automation & Commissioning

Food & Beverage Proudly sponsored by Siemens • Lenssen Dairy Project: One-person milking operation • Process Partners Project: five:am • Rescue Foods Product: Bircher Bars • SAGE Automation Project: Pressureless Conveyor Control and Singuliser Modular Control • Simplot Australia Project: Targeting Energy Efficiency Opportunities • Unilever Project: Streets Ice Cream plant upgrade

Lifetime Achievement Proudly sponsored by LogiCamms Ltd • Ian Gibson IICA • John Keys Schneider Electric • Ken Brown K.E. Brown Electrical Switchboards • Dr Pengfu Tan Xstrata Copper

Mining, Minerals & Exploration Proudly sponsored by Schneider Electric • Columbus Group Project: MiT Mill Seals • EdanSafe Pty Ltd Project: SmartCap Operator Fatigue Management System • iOmniscient Pty Ltd Project: BP (British Petroleum) • Optalert Project: The Optalert Portable System • Hunter Valley Coal Handling And Preparation Plant Project: Advanced Yard Machine Positioning (AYMP) System • Xstrata Zinc – Xstrata Mount Isa Mines Project: Black Star Open Cut Voids Management Procedure • Bonfiglioli Transmission (Australia) Pty Ltd Project: Boom Drives Efficiently Assist Iron Ore Expansion

Oil & Gas Proudly sponsored by AMS Instrumentation & Calibration • BOC Project: Cylinder Maintenance Centre • BJH Controls Project: Fuzzy Logic use in a Fuel Gas Supply Control System • Emerson Process Project: Intelligent Vessel Gauging System • BOC Project: BOC South Pacific GMA and TIG Arc Projectors • Qenos Project: Qenos Altona Olefins Advanced Process Control and Plantwide Feed Maximiser

Green Energy Plant for $120 million Bluetongue Brewery • CST Wastewater Solutions Project: DAF Treatment to Achieve Tough Wastewater Targets • Frucor Project: Vertical Screen Increases Wastewater Treatment Efficiency • Tyco Flow Control Pacific Project: Nepean River Weirs Environmental Flow Release and Fish Passage Control System • Yarra Valley Water Project: Yarra Valley Water Host SCADA Upgrade Project • SAGE Automation Project: State Water iSMART (integrated Surveillance, Monitoring, Automation & Remote Telemetry) SCADA Upgrade Project

Power & Energy Management Proudly sponsored by Schneider Electric

Project: Rio Tinto: earth ground testing for mine sites with Fluke 1625 • PTronik Pty Ltd Project: PTronik pMC Master Controller • Thor Technologies Project: Smart Rack Guard 11 • NEP Solar Project: Biosol3Gen

Young Achiever Proudly sponsored by SICK • Dave McPherson Company: Laser Electrical Ballarat • David Michel Company: Automotion Control Systems • Kyle Dix Company: REDARC Electronics Pty Ltd • Lucya Yunus Company: Xstrata Copper Mount Isa Mines • Sven Huber Company: Tyco Flow Control

[The PACE team thanks all those who • Electronic Power Solutions Pty Ltd entered and looks forward to meeting the Project: Pool A D _Epic PA C Pump E P CEnergy A J USaver N _ 1 2 . pfinalists d f atPthe a Awards g e dinner 1 1 on 5 Thursday / 0 5 / 1 2 , • Fluke Australia June 14 in Melbourne.]

Transport, Power and Infrastructure Proudly sponsored by Honeywell Process Solutions • Aurecon Hatch Project: NCIG Coal Export Terminal Control System • Enerpac Project: Lifting Up Christchurch – Enerpac brings tons of good news for earthquake affected 3-storey building • ICM Airport Technics Australia Pty Ltd Project: Qantas Next Generation Check In • Industrial Control Technology Project: CSIRO Australian Animal Health Laboratory Controls and Monitoring Upgrade Project • iOmniscient Project: KLIA (Kuala Lumpur International Airport) • Enerpac Project: Newcastle Stadium Project • Plantweave Technologies Project: Royal North Shore Hospital Electrical SCADA

Water & Wastewater Proudly sponsored by Endress+Hauser Australia • Bluetongue Brewery Project: Recycled Water Treatment Plant/

JUNE 2012 www.pacetoday.com.au 21

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PACE.JUNE12.PG022.pdf

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FDT 2.0 is primed for the future The FDT standard’s extensibility provides the flexibility to create new software and tools without compatibility issues with new or existing equipment, writes Harry Forbes.

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RC sees a lot to like about FDT technology in general and the new features of FDT 2.0 in particular. Many organizations would throttle development programs to a slower pace once achieving the wide acceptance that FDT has enjoyed in several world regions. However, it appears that the FDT Group has actually increased its work pace to be able to continue to advance the value of FDT to end users and automation suppliers alike. FDT 2.0, released several months ago, is intended to further improve ease of use, scal1 4 / 0 5 / 1 2 , ability, 2 : and 5 5versatility. PM With increasing support from a growing number of suppliers in virtually every category of automation and field device, end users can now deploy FDT with little risk of obsolescence or stranded technology. FDT technology is suitable for all industrial segments today, including process, discrete, and hybrid manufacturing. FDT architecture should also be capable of adapting to any field communication protocol that may be needed in the future. More than 3,000 unique devices are now supported by FDT-certified DTMs that integrate 15 of the most popular field network communication standards, with more in the pipeline. New devices and standards can be added as warranted. More than 80 FDT Group member companies have delivered tens of thousands of devices with FDT capability. The technology enables users to take advantage of more of the capabilities embedded in their installed intelligent instruments – regardless of field protocol, control system, or device supplier. This can help lower both operating and maintenance costs. According to the FDT Group, the standard’s extensibility provides the flexibility to create new software and tools without compatibility issues with new or existing equipment. This gives end users the flexibility to

FDT BaSICS

CommuniCation interfaCe FDT Technology standardises the communication interface between field devices and control systems or engineering and asset management tools. Key features are its independence from the communication protocol and the software environment of either the device or the host system. FDT Technology allows any device to be accessed from any host through any protocol. The FDT interface specification describes the standardised data exchange between devices and control systems or engineering and asset management tools. Devices can be configured, operated, and maintained through the standardised user interfaces integrated in an FDT Frame Application. The usage of FDT can be compared to the printer driver system known from office applications. The printer is delivered with the corresponding driver. That driver implements standardised interfaces so that any office application can make use of it. In FDT, the hardware (the field device in this case) is delivered with a driver called DTM, which has the standardised FDT interface. This enables any FDT Frame Application, for example control system or engineering and asset management tool to use it. [Information courtesy of www.fdtgroup.org]

adopt new enhancements at a pace appropriate for their organization with minimal risk from migration or obsolescence.

Lifecycle ease-of-use

ARC research has shown that new technologies and programs can fall out of favour in plants or factories due to difficulties at any point during the life-cycle.

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ELEMENTS: FDT standardises the communication and configuration interface between all field devices and host systems. FDT 2.0 adds features that can help end users and suppliers manage these issues throughout the field device and FDT product lifecycle. FDT 2.0 uses a Microsoft .NET technology platform that enables fast and easy access to data while providing a stable platform for future enhancements. The Microsoft .NET 4.0 platform is designed to be independent of hardware architectures and operating systems (including OS changes by Microsoft). Other FDT 2.0 enhancements include an updated style guide, pre-tested common components, distributed FDT Frame Applications sharing, and an Integrated Development Environment (IDE) that facilitates development of FDT products. Certified FDT 2.0 DTMs contain embedded, digitally signed proof-ofconformance certifications. Additionally, frame applications can be configured to alert IT administrators when an updated DTM is available, easing support of an installed device. These enhancements work together to improve interoperability, reduce supplier and end user costs, and ensure that all FDT-compliant devices will integrate out of the box with certified FDT frame applications and DTMs.

OPC UA in the future

The planned inclusion of an OPC UA information model to be released in the near future will provide online data exchange between automation systems, asset management systems, and other

plant and enterprise systems and applications. OPC UA technology uses a service-oriented architecture (SOA) that runs on Windows PCs, Linux, and other enterprise-level systems.

Future interopearbility

By integrating FDT and OPC, users will be able to use OPC UA applications to send data to business systems, enhancing the reliability of asset information and providing a comprehensive view of asset bottlenecks that require attention. The FDT Group is also working with other field communication organizations to develop a new FDI (field device integration) standard. The future FDI standard seeks to couple the use of electronic device descriptions (EDDs) with a graphical interface into a new industry standard. The FDT and FDI groups are working in tandem to ensure future interoperability. The FDT Group believes that end users adopting FDT and the impending FDT 2.0 will have a substantial lead over their peers by being able to develop new work processes now that realise the most value from FDT-enabled asset management initiatives. Additionally, because FDT is suitable for all communication protocols, including discrete and sensor buses, end users have the flexibility to include discrete automation assets as their asset management initiatives expand. [Harry Forbes is Senior Analyst, ARC Advisory Group.]

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New from VEGA: Radar level measurement specifically for the water and sewage sector. The radar sensor VEGAPULS WL 61 is ideal for any applications involving distance, level and flow measurement in water preparation and sewage treatment. Completely unfazed by weather or surface conditions, radar technology delivers precise monitoring of water levels, ensuring reliable measurement data and maintenance-free operation. www.vega.com/au/innovation Phone: 1800 817 135

www.arcweb.com June 2012 www.pacetoday.com.au 23

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BEHIND THE SCENES

Significant savings flow from SCU’s in no

A server-based energy and water monitoring database enables multiple stake holders at Southern Cross Univers ity to b

ACED with the escalating the use of resources at the campus. cost of electricity and the Innotech sales manager, Paul continuing push to reduce O’Connor, explains that SCU greenhouse gas emissions, purchased Crompton Integra power enterprises are looking to the latest meters and engaged local contractors to technology for solutions. install them, while Innotech provided At Southern Cross University’s a web based graphical user interface to (SCU) Lismore Campus in north east allow multiple concurrent users to view NSW, a lack of control and detailed and analyse the data. data relating to the use of electricity “Users can see on a daily basis and water was identified and solutions what energy and water each area of the were sought. university is using. This allows performAfter a consultation process, Innotech ance milestones to be set which autoControl Systems Australia was engaged matically flag when the usage trend is to provide its Acquisition & Total likely to exceed targets,” he said. Optimisation Management (ATOM) “The system also allows users to server based energy and water monicompare historic day to day, week to toring A Ddatabase _ P A CtoEenable V A Umultiple J U N _stake 1 2 . p week, d f month P a gtoe month 1 and 3 / year 0 5 to / year 1 2 , holders in the university to better control readings between areas being monitored.

Inefficiencies in resource consumption can be identified to reduce costs and lessen environmental impact. CO2 emissions are automatically calculated and reported. “ATOM is a complete analysis and reporting package which makes you aware of your building performance and environmental impact. into any new or 4 :“It4 can 2 bePintegrated M existing building, or multiple buildings

that currently have no Innotech hardware or software. “A key feature is that it can be enabled as either a standalone solution or as a multiuser web based solution with support for up to five concurrent users via Innotech eServer. “Data is acquired through a Microsoft SQL Server database with either local or remote access. In addition to electricity and water consumption, this system can provide information on gas and thermal energy consumption, and hours run for HVAC equipment. “The SQL Server enables accessible business intelligence across an organisation by viewing data from various sources through dashboards and Sharepoint collaboration.”

You Compress Air. We Make Sure It’s Dry. Optimize your compressed air quality with the right dew point instrument What are your system’s critical dew points? Our unique sensor technologies cover the full dew point range with optimized instruments for practically any compressed air system. Vaisala DRYCAP® and HUMICAP® sensor technologies ensure acccurate, reliable measurements with excellent long-term stability and fast response. For more information, please visit:

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24 www.pacetoday.com.au June 2012

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in novative energy management system

Univers ity to better control the use of resources at the campus, writes Hartley Henderson. Real time monitoring

O’Connor emphasises that ATOM provides a graphical user interface with real time monitoring of system data and coloured indication when forecasts exceed the set targets. “Inefficiencies in resource consumption can be identified to reduce costs and lessen environmental impact. This is a comprehensive data analysis system that incorporates forecasting capabilities, and provides password control with the ability to set multiple level user access,” he added. According to O’Connor, Innotech ATOM software is capable of communicating with building services equipment including A Dwith _ Pvarious A C Eprotocols, ME T J U N_ 1 2 . p d f BACnet MSTP, BACnet/IP, OPC,

CAPTION: SCU facilities supervisor Jeff Braby says that more HVAC controls will be added. Modbus RTU, and Modbus TCP. He also points out that ATOM can be utilised to generate reports and bill tenants for various building services between specific times and dates. This includes the generation of usage reports and activity statements for hours run utilising a tenant/services database that can be customised to suit specific applications.

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O’Connor says that following comple> tion of the basic ATOM works at

June 2012 www.pacetoday.com.au 25

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BEHIND THE SCENES

SCU, Innotech is working with local power meters and 21 RMC Endurance contractors to retrofit HVAC systems at Multijet Turbine water meters have With optimum start a number of buildings in the first stages been installed. routines the plant only of a Building and Energy Management “Each building has a primary power System (BEMS) installation. The main and water meter and in some buildings commences operating buildings involved so far include the old we have captured the HVAC power on at the latest possible library at the Lismore Campus and the secondary meters. In addition, BEMS SCU Tweed Heads Riverside Campus. controls have been installed on some of time before the buildings “These works have already delivered our large HVAC units,” he said. are occupied. significant energy savings to the univer“As time has progressed, the BEMS sity. In addition, we have now developed graphic displays of consumption, a plan with the university to tie all of comparisons, and history has clearly the campuses into the ATOM system, indicated trends and provided valuable and BEMS is being provided to a new feedback to the end user. Energy savings that the plant only commences operbuilding which is under construction at have already been realised through the ating at the latest possible time before the Gold Coast Campus. implementation of the HVAC controls the buildings are occupied.” “This is a system that is easier for and moving forward, more controls will O’Connor believes that further the SCU service personnel to use be introduced. benefits can be delivered by fitting all compared to the outdated systems that “The new Innotech BEMS controls new SCU buildings with BEMS and have been replaced. In the case of the became operational on 25 July 2011 and continuing to expand the number of library, the works also involved adding delivered a drop in electricity usage from power meters at the Lismore Campus to a free cooling cycle and CO2 control 2609kWh on 24 July to 1560kWh on be able to drill down further to where of the outside air volumes to reduce the 25 July. the energy is being used. amount of air introduced, based on the “The difference in total energy usage Substantial savings level of occupancy in the library. between July and August is 23,810kWh. “HVAC A D _ P systems A C E EatLboth E J sites U Nare _ 1 2 . p SCU d f facilities P a g supervisor, e 1 1 Jeff 4 / Braby, 0 5 / 1 2 , When 5 : multiplied 2 9 P Mby SCUs current elecadvises that so far 33 Integra 1630 started using optimum start routines so tricity charges of approximately 18c per

kWh, this represents a saving of $4285 for the month. This is a 16 percent return on investment and should have a payback period within six months, at the current electricity rate. “Our water meters are still to be verified, as some meters have not been in service for long due to the time it has taken to schedule water outages to install them. We have concentrated on power first as these were relatively easy to install. “However, it has been interesting to capture the water and power usage per building, instead of one lump sum reading, and BEMS readings also enable comparisons to be made with bills from the service providers.” Innotech Control Systems Australia 07 3421 9100 www.innotech.com.au Southern Cross University 02 6620 3222 www.scu.edu.au

June 2012 www.pacetoday.com.au 27

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SPOTLIGHT

7best of the

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

Modular level switch By adopting a unique modular concept, TriMod Besta level switches have deviated from older conventional designs and are able to deliver unparalleled reliability even in extreme process applications. TriMod Besta level switches now have IEC Ex Certification in addition to ATEX certificates, thereby enabling them to be used in Ex ed and Ex ia applications in Australia. The three-module design concept comprises the switch module, the flange module and the float module. This enables unlimited level switch combinations that will reliably manage applications requiring high pressure components, self checking switch elements, or corrosion resistant wetside parts. Switch modules are available with electric, electronic or pneumatic output signals. Besta switches are shock and vibration resistant. High and low temperature and explosion proof versions are available. Standard housings offer IP65 ingress protection but IP67 and IP68 options are available for use in extreme environmental conditions. The switches are especially designed for easy installation with a hinged cover, captive screws and the self-lifting terminal clamps. For convenience of wiring, the connection diagram is shown on the inside of the hinged lid. The float modules, like all wetted parts, are made of stainless steel, Hastelloy C or high quality plastics. Control Components 02 9542 8977 www.controlcomponents.com.au

Differential Pressure Switches The ATEX Certified Pyropress Industrial Differential Pressure Switches are suitable for use in harsh industrial environments. This range of industrial pressure switch has been used to monitor filter blockage and air movement through ducting and has been specified for offshore applications. Incorporating a diaphragm and two sealing Belloframs, the switch offers reliable switching action when a differential pressure is required to be sensed. They can, by venting either the HP or LP connection, be used as a low pressure or vacuum switch. Resistors can be incor-

porated for ‘end of line’ and short circuit monitoring. It is available in NC4B 316 stainless steel or black anodised aluminium switchbase to IP66 standards. There is a single or dual microswitch option and the settings range from 0.5 mBar to 10.5 Bar. The switches are designed and manufactured in the UK. Duff and Macintosh 02 9482 1411 www.duffmac.com.au

Pressure sensors feature IO-Link The pressure sensor from ifm efector communicates all data flexibly via switching outputs or IO-Link 1.1. Process data and diagnostic information may be transmitted using a standard cable. Parameter setting of this PN7 type pressure sensor also uses the IO-Link communication technology. An IO-Link master saves the parameters of the connected sensor and transmits them when the sensor is replaced by a device of the same type. This eliminates the need for a new parameter setting. If the IO-Link function is not used, then the pressure sensor operates – as before – with two switching outputs (SIO mode) or a switching output and a diagnostic output. Additionally, the sensor features a very high switch point accuracy and switching frequency and is extremely robust. The overloadprotected ceramic measuring cell even withstands more than 100 million switching cycles. Different versions with pressure ranges between -1 and 600 bar are supplied at a good price/performance ratio. ifm efector 1300 365 088 www.ifm.com/au 28 www.pacetoday.com.au June 2012

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

High-pressure transducers

SIL 3 Safety Relay Weidmullerâ&#x20AC;&#x2122;s SIL 3 Safety Relay has been created for use in the emergency shutdown of plants and plant components in the process industry. The device meets the requirements of EN61508 as well as the demands of Safety Integrity Level 3. The relay ensures safe electrical isolation of the safety PLC to the field and initiates protective measures in dangerous situations or immediately cuts the energy supply. The SIL 3â&#x20AC;&#x2122;s safety and monitoring circuits each have a yellow LED to indicate the functioning of the relay. In the output of the SIL circuit, there is a redundant connection of three relays to guarantee reliable isolation. The safety relay is fitted with gold-plated contacts and an additional switching current range of 6mA up to 5A of the monitoring circuit permanently ensures reliable reaction of the emergency shutdown system. Weidmuller info@weidmuller.com.au 1800 739 988

Setra Systems has introduced the Model 3100/3200 series, a family of compact, low-cost, high-pressure transducers, designed to support the performance demands of high-volume OEM applications, particularly within space constrained environments. Available in standard (Model 3100) and heavy duty (Model 3200) versions, design of the 3100/3200 series incorporates the use of thin-film strain gauge sensing technology in a Wheatstone bridge configuration.

Strain gauge molecular layers are sputtered onto a corrosion-resistant 17-4 PH stainless steel diaphragm. Circuit etching further provides resistor definition and uniformity. This configuration allows for the use of simple, accurate and compact strain gauges to be deposited directly onto the back of the pressure sensing diaphragm. Pryde Measurement 1800 688 211 www.pryde.com.au

H-Max variable speed drives H-Max variable speed drives are suitable for universal use. Their special features make them especially useful in HVAC applications. It has a configurator (wizard) for the two PID controllers and an internal function block that carries out the on and off switching of uncontrolled motors. The drive includes a function that defines its response to a fire. The behaviour of H-Max after a power failure can be configured by the user. The user can define whether a start command is required on restart or the drive is to automatically start up. The typical network protocols used in the air conditioning sector, such as BACNet and Modbus, are provided on board both via RS485 and also as its Ethernet variant. Eaton Industries 1300 332 866 www.eatonelectric.com.au

Wireless I/O for NI CompactRIO National Instruments has unveiled a wireless gateway and two measurement nodes that extend the capabilities of the NI wireless sensor network (WSN) platform. With NI LabVIEW system design software, engineers can easily integrate wired and wireless measurement and control systems and deploy autonomous programs to WSN nodes that perform local control, data analysis and eventbased alarming or notification. Some of the most challenging applications require a solution that combines both wired and wireless measurement and control systems. With the new WSN C Series gateway, NI claims to be one of the only companies that can offer a complete, reconfigurable platform for these hybrid systems. NI 9795 C Series Gateway aggregates measurement data from distributed WSN nodes, making data available within deployed LabVIEW Real-Time applications running on CompactRIO. It adds to existing programmable and nonprogrammable WSN gateways to offer choices for cost and flexibility. NI WSN-3230 (1-port RS232) and NI WSN-3231 (1-port RS485) Serial Nodes feature one serial port and two digital I/O channels for discrete inputs, event detection and programmatic control. National Instruments 1800 300 800 www.ni.com/wsn/whatsnew June 2012 www.pacetoday.com.au 29

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COMMUNITY

TOP TWEETS

WHAT’S ON

Goulburn Technology Expo 13 June 2012, Goulburn nsw@iica.org.au

Here’s what you may have missed this May if you weren’t following @pacetoday on Twitter: o More than a third of large manufacturers are considering reshoring from China to the US http://dlvr.it/1TjJkk

Griffith Technology Expo 13 June 2012, Griffith nsw@iica.org.au

o Dassault Systemes to acquire Gemcom Software International and push into mining sector http://dlvr.it/1Tm2Fm

Yokogawa User Meeting 13-15 June 2012, Broadbeach ron.hartman@au.yokogawa.com

o Emerson acquires Marine Controls Business from Johnson Controls http://dlvr.it/1QNDBG

PAS Alarm Management and HMI Course 21-22 June 2012, Melbourne info@apex-opt.com

o Compact spectrometer allows rapid testing of food quality http://dlvr.it/1WGwjy o Burkert appoints PRTS as its distributor for North Queensland http://dlvr.it/1WHlWH

Network Management with Industrial HiVision 25-26 June 2012, Melbourne wendy.gillies@rmit.edu.au

o Schneider Electric opens new Process Control Lab at Edith Cowan University http://dlvr.it/1WWspC

CISCO Certification Training CCNA1: Network Fundamentals 7 July 2012, Melbourne wendy.gillies@rmit.edu.au

For daily updates visit www.pacetoday.com.au

o World’s first flight in a jet powered by locally produced synthetic fuel derived from coal http://dlvr.it/1WYt3V

o Micro-generator produces energy from flow of water inside distribution pipes http://dlvr.it/1X7z5C o Fieldbus in Hazardous Areas http://dlvr.it/1Y7yJF o Industry loses a respected veteran in the passing of Craig Southwell http://dlvr.it/1YB1vk o Algae.Tec commissions its showcase biofuels facility Shoalhaven One in Nowra http://dlvr.it/1Ynj1P o Lubricate machines with water not oil http://dlvr.it/1Yp425 o Hunter Water Corporation to build a new water recycling plant http://dlvr.it/1ZJBwr o ABB Australia expands motor and generator services business http://dlvr.it/1ZJgCn

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

IICA CORNER

Making a difference Our greatest challenge is providing leadership in benchmarking, writes Brett Simpson. MY TWO previous articles focussed on Education and Networking, two of the three key planks of the Institute of Instrumentation, Control and Automation (IICA).Let’s look at how the IICA addresses its third key platform, Benchmarking. As the professional Institute for persons engaged in instrumentation, control systems and automation (IC&A), we face perhaps our greatest challenges in providing leadership in the area of benchmarking. Resource restrictions certainly curtail our ability to mount and fund the many areas within our industry sectors that we believe warrant the raising of barriers to higher levels of professionalism. Notwithstanding the constraints we face, the IICA is actively focussing 30 www.pacetoday.com.au June 2012

on areas where we believe we can make a difference. Australian and International Standards are the most obvious areas of benchmarking interest to organizations like ours and we are actively engaged in this. We see as very important, the need for our on-going participation in developing appropriate Standards. Another example of our activity in the benchmarking space is our current work in raising the professional barrier in specific sections of the aerospace maintenance areas-both civil and defence. Here the IICA, following a number of industry representations for assistance, is seeking to address concerns about risky behaviour in relation to issues arising from failure to conform to mandatory requirements of the

International Standard AMS2750D. The Institute is in the process of working with RMIT University and with support from the AAAI (Australian Aerospace and Aviation Institute), to put together a series of practical industry-based training courses and a registration scheme aimed at educating mostly outsourced contractors and sub-contractors down the line. Some of them increasingly operate outside the knowledge base of the mandatory requirements and therefore pose potentially serious risks to air safety. The IICA intends to seek support and endorsement for the training and registration scheme from both CASA and its Defence equivalent. The total scheme, will add a practical risk minimisation strategy to the relevant aerospace

maintenance sector, thereby raising the professional benchmark standards for the suppliers, manufacturers and contractors concerned. The IICA sees this kind of benchmarking activity as one in which it sees itself becoming increasingly more active. Put simply, our Institute is positioning itself to take on a more proactive leadership role in raising the standard of professionalism in areas of our interest. The IICA has a large agenda of initiatives and activities it wants to address so that our industry sectors are more visible. Our Institute’s three key planks of Education, Networking and Benchmarking are a sound basis for the IICA to help in achieving those goals. [Brett Simpson is President IICA.] www.iica.org.au

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This 3 day event offers a range of workshops and presentations on the latest technologies, case studies and practical applications from fields such as industrial automation, process and analytical instrumentation, PLCs, DCSs and process control. Some topics include: • Process Optimisation with Ears, Eyes and Brains – Powitec (Germany) • System Information Modelling (SIM) and its Implementation to Fortescue Metals, Solomon Mine Project – I & E Systems • Remote Operation and Monitoring of Origin Energy’s Power Stations – Origin Energy • Applying Wireless Networks in a Legacy System – Dick Morley • How 'Cloud' Technology is Revolutionising Industrial Automation – Rise Technology Solutions Sponsored by:

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