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JUNE 2015 | VOL.68 NO.5
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Welcome to the world of
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JUNE 2015 | VOL.68 NO.4
INSIDE PACE
Cyber Security
Honeywell’s latest security strategies
Post Print Approved PP100008186
Real time asset management optimisation is here
MES
How it can help businesses deal with the generational change of workers
Test & Measurement
Power quality analyser that ramps up the speed
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CONTENTS
Publisher: Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor: Branko Miletic Tel: (02) 8484 0976 Fax: (02) 8484 0722 Email: branko.miletic@cirrusmedia.com.au
IN THIS ISSUE 10
Group Sales Manager: Tim Richards Tel: (02) 8484 0829 Mobile: 0420 550 799 Email: tim.richards@cirrusmedia.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@cirrusmedia.com.au
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Graphic Designer: Louis Santos Email: louis.santos@cirrusmedia.com.au Production Co-ordinator: Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0722 Email: tracy.engle@cirrusmedia.com.au
20 News 7
Innovation New Innovative Manufacturing CRC gets go ahead Insight 8
Manufacturing Execution Systems Helping ‘on-board’ new generation workers SUBSCRIPTION: $99 pa incl GST OVERSEAS SUBSCRIPTIONS: NZ: $A109 pa & OS: $A119 pa CUSTOMER SERVICE: 1300 360 126
Cirrus Media Tower 2, Level 3, 475 Victoria Ave, Chatswood, NSW 2067, Australia Locked Bag 4700, Chatswood Delivery Centre, NSW 2067, Australia Phone: 02 8484 0888 Fax: 02 8484 0633 ABN 80 132 719 861 ISSN 1329-6221 www.cirrusmedia.com.au © Copyright Cirrus Media, 2015
Analysis 10
Asset Management Fighting pipe corrosion Product Focus 12
Latest developments Power for mobile water disinfection DAF treatment and biogas Awards 20
Women in Industry 2015 The finalists are announced Operations 22
Plants & Refineries Operation and control of flares
Test & Measurement EZ-Broadware range; Eddy current sensors; Bench-mounted analyser; Power quality analyser; Vibration meter; Electronic volume corrector; Mobile data recorder
New Products 26
In Focus 16
The Last Word 30
Cyber Security Honeywell’s latest security strategies
Latest releases Software for operational efficiency Electronic starter OTDC switch disconnectors Plant Management Software The benefits of simulation software
ON THE COVER
The benefits of simulation software
JUNE 2015 | VOL.68 NO.4
INSIDE PACE
Cyber Security
Honeywell’s latest security strategies
Real time asset management optimisation is here
Post Print Approved PP100008186
OFFICIAL MAGAZINE OF:
Average Net Distribution Period ending Sept ’14 5,725
Waste & Water Management 18
MES
How it can help businesses deal with the generational change of workers
Test & Measurement
Power quality analyser that ramps up the speed
A network of integrated software tools is vital to ensure internal resources of companies operating within the Metals, Mineral and Mining sector are properly managed with a continuous view of their assets along the entire supply chain. Simulators can provide an off-line or on-line virtual environment which mimics the process plants and all its function, thus enabling scalability studies, control architecture design and validation, process optimisation, control systems tuning, operator training and ‘what if’ scenarios. Maintenance teams can also use these simulators to test system checkout for start-up,
conduct operator training and safely operate the facility. An operator training simulator integrated with a plant’s real control system graphical interface also allows an operator trainee to become familiar with all aspects of operating a facility from a familiar yet totally risk-free environment. An example of this software is SimSci from Schneider Electric which provides operators and trainees with a single continuous view of assets along the entire supply chain – from extraction to delivery. (See page 30) JUNE 2015 www.pacetoday.com.au 5
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COMMENT
WHAT’S ON
EDITOR’S MESSAGE
PACE Zenith Awards 11th June 2015, Sydney www.paceawards.com.au
Humans rarely needed...except...
2015 Women in Industry Awards 25 June 2015, Sydney womeninindustry.com.au
THE Internet of Things (IoT) or the ability to transfer data over a network without requiring human-to-human or human-to-computer interaction is currently very much a trending topic. However there are still enough uncertainties around its applications and viabilities to conclude it’s going to take a lot to convince manufacturers that they need to go out and splurge on the latest and greatest IoT-ready devices and associated analytics software. Instead, they need to fully grasp the real value of Big Data as well as Advanced Process Control (APC) and what it can and cannot bring to their business. This in itself is not a task for the fainthearted - the sheer volume of data generated by continually
Fundamentals of Process Safety 13-17 July 2015, Brisbane www.icheme.org/fpsbris Practical Process Control Techniques Course 27-29 July, Perth www.apex-opt.com
Branko Miletic Editor
APCChE 2015 Congress Incorporating Chemeca 2015 27 September – 1 October 2015, Melbourne www.apcche2015.org
Next Issue
For daily updates visit www.pacetoday.com.au
• PACE Zenith Awards: Winners Issue • Energy Management • SCADE & MES • Process Control in Oil & Gas • Security Systems • Focus on Fieldbus
controlling a process, any process for that matter, is simply astounding. This is because multiple factors can affect an APC system since it requires data not just from process control specific inputs but also from process measurements and process metrics (KPIs) that may or may not directly be used by the APC system. Its Big Data meets Big Headache and it’s the one issue that affects all manufacturers, big, small or in-between. It also means that changes are needed, and it’s these changes that we will focus on more and more in PACE magazine as time goes on. Speaking of changes, you’ll notice there’s been a change in this magazine’s editorship. As of this issue, I’ve taken over the reins of what
is undoubtedly Australia’s premier process and control publication - one that has served the process, test and instrumentation sectors for a quarter of a century. So while I do have a manufacturing background, I’m also well aware that nothing compares to having current real life exposure to the process and control sector, along with dealing daily with all its complexities. On that point I invite readers to keep me posted on what issues matter to them and how they affect their businesses, and I’ll do my best to give them the scrutiny they deserve. We’ll talk soon. branko.miletic@ cirrusmedia.com.au Like us on Facebook and join the conversation facebook.com/PACEtoday
DISTRIBUTION MANAGEMENT
Schneider Electric named a leader in distribution management Gartner has positioned Schneider Electric as a leader in the Magic Quadrant for Advanced Distribution Management Systems (ADMS) for two consecutive years. Additionally, in Gartner’s report for Critical Capabilities for Advanced Distribution Management Systems,
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Schneider Electric achieved the highest product score for all three use cases: Improving Outage Response, Optimising Grid Operation, and Managing DER Impacts. Gartner reports, including the Gartner Magic Quadrant, are well regraded as competitive comparisons in
the information technology industry. Magic Quadrant reports offer in-depth analyses and visual summaries of the direction and maturity of markets and key vendors. “We consider our position as a leader as a confirmation of our mission to offer utility customers the tools to
manage growing demand and peak loads, integrate more renewable energy into the grid, and improve electricity quality and availability from control centre to customer,” said Jean-Pascal Tricoire, Chairman and CEO, Schneider Electric. www.schneider-electric.com
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NEWS
INNOVATION
New Innovative Manufacturing CRC gets go-ahead LONG-AWAITED funding of $40 million for the Innovative Manufacturing CRC (IMCRC) was announced at CRC Association’s annual conference. As some had speculated, industry minister Ian Macfarlane chose the 25th annual CRC Association event to announce funding for a seven-year term of the IMCRC. The minister also said the CRC for Optimising Resource Extraction would gain continued funding of $34.45 million to June 30, 2021. “CRCs are a highly successful way of bringing industry and research organisations together to apply the latest research knowledge to the real-world problems facing industry,” said Macfarlane at the event. “More than 60 organisations, including multi-nationals, SMEs and peak industry bodies, will be
Industry Minister Ian Macfarlene announced seven years of funding for the Innovative Manufacturing CRC. involved in these CRCs.” The IMCRC was a combined re-bid of the Advanced Manufacturing and Manufacturing Industry
Innovation CRCs, which followed the suggestion of the government in February last year. It will concern knowledge-intensive industries including additive manufacturing, lightweight robotics and medical devices. The length of time taken to release funding for the manufacturing CRC has been criticised by the opposition, with shadow industry minister Kim Carr saying in April that it “should have happened months ago.” Following Macfarlane’s confirannouncement, Carr said the minister, “Left the announcements on his desk for eleven and five months respectively, just so he would have some good news to deliver at the annual CRC conference.” The announcement also follows the recent release of a review by David Miles of the CRC program.
This contained 18 recommendations to more closely link research projects to “practical and commercial outcomes”. All recommendations were accepted by the government. Macfarlane said both CRCs would be aligned with the new Industry Growth Centres, announced last October. “Along with Industry Growth Centres which focus on the areas in which Australia has a competitive edge, CRCs will drive productivity, innovation and collaboration gains, and identify commercial opportunities to exploit global markets and generate new jobs,” he said. The ORE and IM CRCs headquarters will be in Brisbane and Melbourne respectively.
Implementing a calibration system?
CRC Association 02 6273 0624 crca.asn.au
AMS AMS INSTRUMENTATION & CALIBRATION PTY LTD Unit 20, 51 Kalman drive Boronia VIC 3155 AUSTRALIA Phone: +61-3-9017 8225 Fax: +61-3-9729 9604 E-mail: sales@ams-ic.com.au Internet: www.ams-ic.com.au
Our calibration and IT expertise helps you face calibration process improvement projects that are typically complex and consume a lot of time and resources. Only 20% to 30% of a calibration system upgrade is tools and technology, the rest is business culture and process. Therefore, the success of a new calibration system depends especially on the implementation of the system and the ability to define and adopt a new calibration process. Learn more at: beamex.com/CalibrationProcessImprovements
www.beamex.com info@beamex.com
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INSIGHT
MANUFACTURING EXECUTION SYSTEMS
Helping ‘on-board’ new generation workers As one generation of workers retires, employers need to ensure the next generation is brought up to speed with as little disruption as possible. MES can help them do this. Janice Abel reports. RECENT ARC Advisory Group research indicates that the improving global economy and population dynamics were major influencing factors in the manufacturing execution systems (MES) market in 2013 and 2014. Improving economic conditions, uncertainty in the European manufacturing sector, oil and gas price declines, and geopolitical issues – all affected market growth. Lower oil and energy prices contributed to more consumer spending and demand for consumer products result in an uptick in many industrial markets in 2014 and 2015. Population dynamics, including the impending retirement of the Baby Boomer generation of workers and the associated need to quickly ‘on-board’ the next generation of workers in factories and other industrial plants and facilities are helping drive demand for MES solutions.
Demographic changes
Loss of worker knowledge due to a retiring workforce and inexperienced workers impacts manufacturing industries in both developed and emerging economies. Many managers facing retirement will not embark on a new project unless there is a relatively low risk of failure and ROI is relatively easy to attain and document. In lieu of this, they would prefer to focus their limited time on incremental updates to existing applications, rather than embark on new projects. However, due to cybersecurity complications related to many legacy systems, there is often no option available except to implement new MES applications. The demand for MES will continue as new-generation workers get more automation experience, economies stabilize, and companies release capital. Today’s production processes and products are increasingly complex, global, and multi-faceted, challenging many manufacturers to find methods to simplify and streamline complex processes while maintaining product 8 www.pacetoday.com.au JUNE 2015
Workflow enforcement
Many soon-to-be-retiring workers have 30 to 40 years of knowledge and experience to pass on. quality and encourage innovation. Product and process complexity, innovation, manufacturing intelligence, analytic tools and ease of use (including ‘app-like’ functionality) drive MES growth. Companies must figure out how to capture the knowledge and experience that will be leaving as the baby boomers retire. Companies can utilize the intelligence provided by MES systems to enable newer, less-experienced personnel to make better decisions. The response to the retirement trend is multi-faceted. Some manufacturers are making a strong effort to integrate MES into their processes; others are just ignoring the problem, possibly due to poor planning or recent economic conditions. However, the problem is not going away – so companies need to address the issue.
Retiring workforce
Many soon-to-be-retiring workers have as much as 30 to 40 years of knowledge and experience. One way to transfer this information quickly to new workers is to utilize software that integrates the data, analysis, intelligence, and decision making with the process. MES can
help enforce workflow standards and responses to abnormal conditions and therefore improve overall performance for all generations. As “digital natives,” the newer, techsavvy Millennial workers do best with modern software. As manufacturers face challenges in skill gaps and shortages of skilled workers due to the retiring workforce, recruiting and retaining a younger generation of worker is essential.
Tech savvy workers don’t want to use old technologies... One key issues for many companies is finding workers that can fill the skills gap. One user told ARC that the new tech savvy worker generation “does not want to work on the old technologies, so keeping older systems running is increasingly problematic” and a driver for MES purchases. Interactive, immersive, and up-todate software tools can help companies meet the expectations of the next generation of manufacturing employees.
Workflow software that improves and enforces work processes is another important reason for implementing MES. In the past, workers were expected to be knowledgeable about work processes. But due to today’s high turnover rates, workflow software must be more intuitive and include the necessary intelligence to enable complex workloads and guide workers. Dynamic engine rules for workflow are being integrated within MES that can help workers make the right decision, which should help inexperienced workers gain experience quickly. Other workflow solutions are being used to address batch processes.
MES solutions evolving
As the manufacturing environment continues to change, MES solutions are evolving by integrating new technologies and solutions to meet new demands and expectations. Future manufacturing processes will be more connected than ever, smarter and have highly intuitive software solutions that predict outcomes, anticipate needs, and provide tools that can provide insight for better, faster and more accurate decisions. Wearables such as digital watches will be incorporated into the daily work routine. These, and many other characteristics, help make evolving MES solutions attractive and effective for the new workforce. [Janice Abel, principal consultant with ARC Advisory Group, researches collaborative production management systems and manufacturing execution systems for process, discrete, and batch manufacturing applications.] ARC Advisory Group www.arcweb.com
PA0615_000_PHO
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TRIO POWER SUPPLIES
Standard functions combined with high quality & reliability
NEW
YOUR ADVANTAGES
High system availability due to robust design
Space savings in the control cabinet thanks to the narrow design
Reliable starting of heavy loads with dynamic boost
Quick and easy installation due to push-in connection
MAIN FEATURES
High shock, vibration and electric strength
Dynamic boost supplies 1.5 times the nominal current for 5 seconds
LED and relay contact signal DC OK
Temperature range: -25 °C ... +70 °C, start-up: -40 °C
Output voltage: 24 V DC ... 28 V DC, configurable
For additional information call 1300 786 411 or
phoenixcontact.com.au/trio
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ANALYSIS
ASSET MANAGEMENT
Fighting pipe corrosion A practical how-to for halting pipe corrosion in oil and gas by the Australasian Corrosion Association. AS the global economy continues to grow the markets for petroleum products continue to expand. To meet increasing demand, more and more oil and gas infrastructure is being built. Corrosion poses a threat to all infrastructure and the economic impact of all types of corrosion and it’s degradation of infrastructure, such as pipelines, oil rigs and towers, represents an annual cost of many millions of dollars to the industry. Pipelines vary from simple steel tubes to state-of-the-art spiral-wound, flexible lines, with diameters ranging from 50 millimetres to two metres. Pipelines are integral to the oil and gas industry, where they form the gathering systems joining wells to process facilities and the distribution system delivering product to refineries and markets. Whilst non-ferrous materials such as fibreglass and polypropylene can be used in non-critical, low pressure applications, the overwhelming majority of petroleum pipelines are constructed from metal. Whether buried or on the surface, all metal pipelines are exposed to a range of physical, climatic and chemical environments that can cause corrosion.
Legacy pipelines
Aging or damaged infrastructure presents many challenges to the oil and gas industry and regulators worldwide. There are thousands of kilometres of pipelines associated with the oil and gas wells and platforms operating in more than 50 countries around the world. These facilities vary in size, shape, and degree of complexity. Much of this infrastructure was built in the 1950s and designed in accordance with lower standards than are currently prescribed. Some facilities are operating well beyond their intended service life and others have suffered damage as a result of storms or accidents or, because of the lack of active maintenance programs have deteriorated to the extent that there is now doubt as to their continued structural integrity. Oil and gas pipelines are often coated 10 www.pacetoday.com.au JUNE 2015
The oil and gas industry invests large sums of money in the design, laying and protection of pipelines. with several layers of protective material and fitted with cathodic protection devices that inhibit corrosion. Internal pipe maintenance and cleaning PAis usually conducted by sending a scrubbing device or ‘pig’ (originally named because of the squealing noise early versions made as they traversed the line) through the pipeline at regular time intervals. Other, more sophisticated pigs, fitted with cameras and sensors, are able to inspect the integrity of welds and the internal condition of the pipe as they move along. Achieving the most effective corrosion control strategies is likely to require changes in industry management and government policies. Industry must take advantage of future developments in protective coatings technology in order to reduce the overall cost of corrosion. Advances in corrosion protection will include coat-
ings that are both physical barriers and contain corrosion inhibitors that are released when a coating becomes damaged or in the presence of a corrosive environment. Historically, metallic zinc and primers containing chromate have provided excellent corrosion protection. These materials have properties that allow coatings containing them to actively respond to a corrosive environment while maintaining a barrier to that environment.
New technologies
Advances in coating technology can offer significant cost savings if developed and successfully demonstrated. Zinc, polyurethane and powder coating technologies make them a superior alternative to epoxy resin technology for longer-term service life. Zinc gives a very basic cathodic protection effect as a thin coating, polyurethane
is effective and aesthetically appealing, while powder coatings can meet the environmental and regulatory challenges. All companies are striving to reduce maintenance budgets for their infrastructure while optimising performance, so new corrosion protection materials must be cost effective and non-hazardous. Some of the latest advances in coating technology has been development of protective coatings that can respond to damage and changes in the external environment. However, such coatings must not be a threat to the environment and maintenance personnel and ideally must be applied using conventional methods currently used to coat structures for environmental protection. New materials such as nano-structured materials and organic metals may be appropriate as the basis for developing damage-responsive coatings and structures. Internal corrosion controls for gas pipelines includes reducing the water
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Helping to put you in Control Modbus Memory Module
content of the gas and adding inhibitors to the fluid flow. For oil pipelines, internal corrosion is mitigated by reducing the water content then adding corrosion and scale inhibitors, and biological controls. Pipeline operators must continually monitor the effectiveness of their chosen corrosion controls. Erosion in the internal pipeline wall can be controlled by removing solids from the stream and by the mechanical design of the layout. Corrosion caused by moisture in a gas stream can be controlled by decreasing the dew point of the gas to a temperature below the lowest operating temperature likely to be encountered in the pipeline. One way to allow for corrosion is to make the pipe wall thicker to provide additional metal for corrosion loss. The corrosion allowance should anticipate the maximum metal loss over the life of the pipeline and ensure that sufficient wall thickness remains to enable the pipeline to operate safely. A corrosion allowance should not be a substitute for other corrosion protection measures since actual corrosion rates in practice can be much higher than those used in the estimation of the corrosion allowance. The oil and gas industry invests large sums of money in the design, laying and protection of pipelines.
The KTA-299 provides 64k of non-volatile memory, accessible via Modbus RTU. Internal memory uses FRAM, which doesn’t wear out when read or written to. Ideal for data logging, storing accumulators & saving counters. 8 to 28 VDC powered. DIN rail mountable. SKU: KTA-299 Price: $249 ea + GST
6-Button Pendant With ER Stop Industrial grade, IP66, 6-button control station pendant comes with ER stop pushbutton. It has contact rating up to 6A @250VAC. 2, 4 & 8 button models, with or without ER stop button, are also available. SKU: HNE-1062 Price: $87.95 ea + GST
125mm Siren IP55 rated, small rugged siren with 5 selectable sounds. It comes with a built-in adjustable volume controller from 95 dB to 105 dB. 24 VDC powered. SKU: QLL-3002 Price: $139.95 ea + GST
Multi-Level Signal Tower
Industry must take advantage of future developments in protective coatings technology. more than 95 per cent of support points on a typical structure. One alternative is to weld a part of the pipe, which is usually free to move, directly to the support structure. This is a common approach for insulated piping systems. There are a number of other alternative pipe supports, such as
Little attention is paid to the mounting and bracing structures that support and guide pipelines. In comparison, far less attention is paid to the mounting and bracing structures that support and guide a pipeline. One of the most common support methods is to lay the pipe on to a standard structural element such as an I-beam or metal channel and secure it in place with a stabilising U-bolt. A similar method is to use a saddle clamp, where the pipe is clamped between two rolled plates, with one of the plates welded to a structural element. These two categories account for
flange bolt supports, various type of pipe hangers and other specialtytype supports. Not surprisingly, it is the beam supports and the saddle clamps that cause the majority of problems. Visual inspection and other non-destructive testing is often difficult and it is virtually impossible to paint or otherwise maintain some areas of the pipe at the support. Some of these support types may even develop bi-metallic contact. Despite both the pipe and support being steel, the
metallurgical differences can still provide a small potential difference to create a corrosion cell. The shape of a cylindrical pipe on a flat surface forms a crevice where moisture gathers and evaporation is restricted. The moisture softens the paint, which fails and exposes bare metal which is then in constant contact with water. Once corrosion starts there can be rapid wall loss leading to eventual failure of the pipe. An effective way to reduce corrosion risk is to minimise the contact point between the support and pipe so that no crevice is formed. Water cannot be trapped, so corrosion no longer occurs. With minimal contact, air can also circulate and evaporate moisture beneath pipes, and it’s far easier to inspect the contact area. If the material of the support is non-metallic, the pipe can be electrically isolated so there is no contact between dissimilar metals. Australasian Corrosion Association 03 9890 4833 www.corrosion.com.au
IP65 rated multi-level signal tower comes with 3 x 70mm dia. LED colours: red, yellow & green. SelectaEOH FRQWLQXRXV RU ÀDVKLQJ PRGH VAC/DC powered. Includes easy pole mounting hardware. 85 dB buzzer is optional. SKU: QLL-1033 Price:$174.95 ea + GST
3 kW Contactor The Teco CN series contactors are designed for 3-phase DOL motor starting. Fitted with auxilliary NO contact. Coil available 24/240/415 VAC.DIN rail or panel mountable. Contactors up to 11 kW available. SKU: TER-501 Price:$24.95 ea + GST
Anemometer The Davis Instrument 7911 anemometer measures wind speed & direction. Rugged components, sealed stainless steel bearings for long life. Mounting hardware is included and 12 m cable. SKU: ANM-001 Price: $183.15 ea + GST
AirGate Modbus Monitor your RTU Modbus slaves over a wireless network using the Airgate gateway. Mini USB & RS-485 interfaces, 10 to 35 VDC powered. SKU: NOW-001 Price:$449 ea + GST
For OEM/Wholesale prices Contact Ocean Controls Ph: (03) 9782 5882 oceancontrols.com.au Prices are subjected to change without notice
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PRODUCT FOCUS
TEST & MEASUREMENET
Bench-mounted analyser MICHELL Instruments has launched its most flexible and adaptable bench-mounted analyser. The XGA301 can be configured to use either zirconia oxide or electrochemical cells to measure oxygen and/or infra-red technology to measure other gases such as carbon dioxide, methane and carbon monoxide. Optional moisture measurements are also available with Michell’s Easidew Ceramic Impedance sensors for moisture content (ppm) or dew point temperature. For further flexibility, any two of these measurement cells can be combined in one unit. The cost-effective industrial gas analyser is suitable for applications where both oxygen and moisture measurements are required.
The different types of sensing cell available mean a wide variety of applications can be addressed by instrument including laboratory testing, leaks in glove boxes, testing the purity of inert gases and other research experiments. The unit is also suitable for use in industry for applications such as reflow oven monitoring, nitrogen generation and food production. The analyser has many options including an internal sample pump, flame arrestor and has a simple to use HMI with an intuitive menu structure. AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au
Suitable for applications where both oxygen and moisture measurements are required.
Eddy current sensors EDDY current sensors with embedded coil technology offered by Bestech Australia differ The sensors are embedded in an significantly from traditional sensors on inorganic carrier material. the market that normally use a wound coil. The sensor itself is embedded in an inorganic carrier material. Electronic components can be positioned on the carrier material. This technology has been developed by Micro-Epsilon for customised applications, which have high requirements in terms of temperature and long-term stability, as well as excellent repeatability. As this technology has been tested in OEM applications for several years, it can now be applied to standard eddy current sensors. ECT-sensors are even suitable for extremely harsh environments. At temperatures up to 180°C, these sensors are permanently applied. The version with an integrated high temperature cable can also be used in temperatures up to 350°C. They are available with the new high performance eddyNCDT DT3300 controller. Bestech Australia 03 9540 5100 www.bestech.com.au
SCADA SYSTEMS PC & PLC PROGRAMMING Wee ooffer W ffee cost effective solutions for your automation ff technology tech te chno noll needs Australia wide. At IIS&E S&EE we specialise in systems integration and S& auto au toma ma automation projects, big and small. For mor more information phone us on 07 3856 2232.
INDUSTRIAL SOFTWARE & ELECTRONICS Tel: (07) 3856 2232 Fax: (07) 3355 1012 E-mail: info@industrialsoftware.com.au Web: www.industrialsoftware.com.au 12 www.pacetoday.com.au JUNE 2015
They are fully auto-placeable and easy to install.
EZ-BroadWare range HARWIN’S SMT, EZ-Test Points are low in profile with a small PCB footprint, making them ideally suited to applications where space is at a premium such as the medical, aerospace, industrial, instrumentation and control systems industries. They provide secure connection points, allowing test engineers to attach industry standard micro test clips which eliminate the risk of PCB and component damage. They are fully auto-placeable, minimising installation costs and are available in three sizes - the largest size is suitable for standard test clips and hooks and the 2012 and 1608 sizes are suitable for micro test clips. These components are specific targets for test engineers to use, permitting a clip-on facility and allowing hands-free testing. The test points are also effectively sacrificial – any damage to them during testing does not affect the final PCB function, as they are additional circuit elements. Clarke & Severn Electronics 02 9482 1944 www.clarke.com.au
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PRODUCT FOCUS
Power quality analyser
Vibration meter
THE Hioki PW3198 power quality analyser has a sampling frequency of 2 MHz and can catch a voltage glitch as short as 0.5 microseconds. According to the company this is ten times faster than its nearest competition. It is a four-channel, three-phase 3- and 4-wire, Cat IV (600 volt) instrument capable of harmonic and inter harmonic measurements to the The power quality analyser is compliant 50th and 49.5th orders (including power with the latest IEC requirements. harmonics) respectively (including phase angles) for both voltage, current, voltage and current unbalance measurement, as well as K-factor measurement useful in assessing transformer loading. In addition inrush current and transient over-voltage impulses (to 6 kV), voltage swell and dip as well as flicker measurement are part of the suite of measurement protocols. The power quality analyser is compliant with the latest IEC requirements, i.e.: IEC 610004-30 Edition 2, Class A standard thus making the instrument suitable for power line analysis acceptable to distribution authorities. It provides numerical displays, voltage and current waveforms and phasor displays indicating unbalance, negative sequence and zero sequence components; as well as trend displays of selected parameters including frequency variation, voltage stability, flicker, harmonic trends, etc.
THE Fluke 805 FC vibration meter is a portable multi-function vibration screening tool that provides quantifiable information on the bearing and overall health of motors and other rotating equipment, and shares that data in real time via Fluke Connect. It is recommended for frontline mechanical troubleshooting teams that need reliable and repeatable measurements of rotating equipment to make imperative go/no-go maintenance decisions. It automatically saves vibration data wirelessly to Fluke Connect cloud storage so authorised
Power Parameters 1 800 623 350 www.parameters.com.au
The vibration meter has a unique sensor tip design that minimises measurement variations caused by device angle or contact pressure.
team members can view all of the measurement data for each asset with the Fluke Connect app on their mobile devices before they leave the inspection site. The handheld vibration meter measures overall vibration from 10 to 1,000 Hz and provides a fourlevel severity assessment for overall vibration and bearing condition. It detects peaks in the vibration signal readings of roller bearings from 4,000 Hz to 20,000 Hz, and uses a proprietary algorithm to interpret severity to determine if the bearing is going bad. It features an infrared sensor that automatically measures surface temperature and displays it along with the vibration reading for a broader understanding of machine health. Fluke 1300 296 625 www.fluke.com
IT‘S A GOOD FEELING TO ALWAYS KNOW WHAT YOU CAN RELY ON.
Sensors. Systems. Network technology.
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PRODUCT FOCUS
Unbeatable Control, Precision, and Flexibility
Electronic volume corrector Honeywell Process Solutions has introduced a new metering device that is designed to more accurately measure natural gas delivered to industrial customers, helping them meet government and industrial standards. The EC 350 PTZ gas volume corrector allows for precise measurement in a design that is easy to maintain and reliable over extended operations. It is the first member of a new HPS family of purpose-built, high-performance electronic volume correctors (EVCs) that meet these critical requirements. The EVC uses pressure, temperature and compressibility factors to more accurately measure gas volumes. Users can program this universal bracket-, wall- and rotary-mount device in the field, and employ its multi-line keypad interface for simplified operation. The new EVC offers improved accuracy, expanded memory and battery, advanced diagnostics, and integrated cellular communications. Key to the EVC’s updated design is a highly accurate, plug-and-play digital pressure transducer and an enclosure optimised for serviceability and outdoor operation. With long-term stability and extended battery life, this solution minimises the need for site visits by technicians and simplifies field repairs. It also allows for very precise measurements and long-term reliability with minimal maintenance requirements.
Helps gas distributors optimise custody transfer.
Honeywell Process Solutions 1800 456 066 www.honeywellprocess.com
Mobile data recorder
NI LabVIEW system design software and reconfigurable I/O (RIO) hardware lower cost and shorten design time by integrating motion, vision, and I/O within a single software development environment.
Accelerate your productivity at ni.com/ industrial-control-platform Australia: 1800 300 800 New Zealand: 0800 553 322
©2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. xxxxx
14 www.pacetoday.com.au JUNE 2015
Recording data from a range of products is now easier with the release of a new product from global test and measurement group HBM. The GEN3i data recorder, part of the Genesis High Speed family, offers a virtually unlimited range of application possibilities. And its compact dimensions make it ideal for mobile use – whether for troubleshooting, maintenance, or commissioning of generators, turbines or engines. The data recorder is also the right instrument for use in the laboratory, in power test stands, or destructive material testing. According to the company, recording, saving and visualising millions of measurement data points per Up to 96 input channels, fully configurable to your needs. second places special demands on the measurement data acquisition system. With this data recorder, you gain total control of your measurement data. You can access all data handling functions with a single touch of the large, intuitive touchscreen. The graphical user interface is simple and easy to understand, and GEN3i enables users to start measuring immediately. Data is transferred directly to the storage medium at speeds as high as 200MB/s. In addition, up to 96 input channels can be configured as required and data can be continuously transferred to hard disk. In addition, fast sweeps can be recorded. Twenty-one different data acquisition cards are also available – e.g. with a 1000 V direct input voltage or sampling rates of 100 MS/s. HBM Test & Measurement 02 9989 8070 www.hbm.com
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IN FOCUS
CYBER SECURITY
Cyber hygiene & peace of mind Cyber security needs to be taken seriously. And, as Matt McDonald writes, it is not just the high profile targeted attacks that industry needs to watch out for.
I
n 2010 ‘somebody’ carried out a cyber-attack on Iran’s nuclear program. They did so with Stuxnet, a drone-like computer virus that was more sophisticated than anything that had come before it. And they successfully destroyed one fifth of the nation’s nuclear centrifuges. The attack attracted plenty of attention and raised plenty of legitimate fears about the future of warfare and the possibility of cyber terrorist attacks. This cyber-attack led to concerns about not just the security of nuclear installations but also of other large industrial plants in the mining, energy, and oil and gas sectors. Should those sectors be preparing themselves for another Stuxnet? “That was a targeted attack,” Chee Ban Ngai who leads Honeywell’s Industrial Cyber Security business in the Asia-Pacific told Manufacturers’ Monthly. While these are obviously a concern, he said, non-targeted cyber threats are also a major problem. “What we are very worried about is cyber threat intrusion that [arise] from the use of poor practices from the engineers and operators in plants,” he said. “We are talking about contaminated USBs or ensuring the hygiene of a laptop that a vendor brings into a plant.”
High stakes
Ngai pointed out that the stakes are high in the mining, oil and gas, and energy sectors. “We’re talking about chemical reactions. We’re talking about the environmental impact. We’re talking about the risk to human safety.” And on top of this, he said, these industries are crucial to the nation’s economic wellbeing.C Ngai explained that, in terms of cyber security, these industries all face the same types of threats. There is nothing unique to any of them. “The common denominator that they face is that they are quickly migrating out from the proprietary process control systems,” he said. “Most of them are in the midst of introducing open system architecture. Many of them are upgrading windows servers and windows operating systems as part of the platform to manage the control environment.” And the moment they decided they decided to make those changes they opened themselves up to increased cyber risks.
Risk Manager
To deal with this increased risk, in recent years Honeywell Process Solutions has invested heavily in cyber security. For example, the company recently 16 www.pacetoday.com.au JUNE 2015
Risk Manager uses advanced technologies that translate complex cyber security indicators into clear measurements and key performance indicators.
launched the Honeywell Industrial Cyber Security Risk Manager, a digital dashboard designed to proactively monitor, measure and manage cyber security risk for control systems for refineries, power plants and other automated production sites. Ngai explained that the approach the company uses is to first provide customers a cyber-security assessment in order to uncover any threat they are facing. If found, these are reported to management and remediation is provided. “Risk Manager comes in very nicely after that because what we can see then is that the plant… will have achieved a baseline security level, sort of like a clean slate…when the risk manager moves in and starts monitoring the system,” he said. Risk Manager uses advanced technologies that translate complex cyber security indicators into clear measurements and key performance indicators, and provides essential information through an easy-to-use interface. The intuitive workflow allows users to create customised risk notification alerts and perform detailed threat and vulnerability analysis so they can focus on managing risks that are most important for reliable plant operations. “It empowers customers. It allows them to have a more participative role instead of relying on security experts to watch over them,” Ngai said. With Risk Manager, he added, they can watch over themselves “and of course escalate for higher support
if they find something which is beyond their means to address.”
Cyber Security Lab
In an effort to advance its development and testing of new cyber security technologies the company also recently opened the Honeywell Industrial Cyber Security Lab in the US city of Duluth. The lab includes a model of a complete process control network that Honeywell cyber security experts will leverage for proprietary research, hands-on training, and to develop, and test industrial cyber security solutions. This lab will help accelerate development time of new cyber protection technologies and speed availability to customers. “Most importantly, the lab will allow us to certify our methods, our solutions, our approach, such that we can quickly roll them out to customers when we carry out the cyber security investment,” said Ngai. Concluding, he explained that no nation is immune to cyber security threats. “When we carry out assessments…from Australia, to New Zealand, to Malaysia, the ASEAN countries, even to India one of the common things we see is that there is a huge catch up to do in terms of basic hygiene.” Given the importance of the resources sector to Australia, the problem is worth taking seriously. Honeywell Process Solutions 1800 456 066 www.honeywellprocess.com
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Don’t miss your chance to be part of this year’s Australian Mining Prospect Awards! Nominations are closing soon for the 12th Annual Australian Mining Prospect Awards, to be held in 2015, so nominate today to be a part of one of the biggest nights in the Mining industry! A total of 13 awards will be up for grabs on the night, highlighting company’s innovation and excellence in the mining industry. All finalists will receive free publicity in Australian Mining Magazine and two free tickets to the gala dinner where the winners will be announced.
The categories for 2015 are: • Community interaction • Contract mining of the year • Contribution to mining • Hard rock mine of the year • Coal mine of the year • Excellence in environmental management • Excellence in mine safety OH&S • Explorer of the year • Manager of the year • Minerals processing of the year • Innovative mining solution • Young achiever of the year • Mine of the year
MINING:AUSTRALIA’S MOST RENOWNED INDUSTRY For more information about the nomination process please contact Cole Latimer, editor for Australian Mining magazine cole.latimer@cirrusmedia.com.au or 02 8484 0652 or visit www.prospectawards.com.au Platinum Sponsor
Sponsors
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WASTE & WATER MANAGEMENT
Power for mobile water disinfection OFF-GRID and mobile water disinfection is now possible thanks to a unique product recently released by Australian water disinfection specialists, UV-Guard. A PLC operated controller packed with integrated features, including the ability to operate on 12V and 24V DC power supplies, now gives UV-Guard’s off-grid and mobile customers the ability to disinfect water via UV treatment. UV-Guard Principal Water Treatment Engineer, Luke Chamberlain, said the company worked closely with customers to ensure the new controllers met their needs. The 12V and 24V DC function was the final option to be added to the new controllers boasting a number of features. “This option has been added after receiving a number of enquiries from operators of solar powered buildings and other customers who require UV disinfection but are off the grid. We have
UV-Guard customer James Galbraith with his UV unit compatible with his off the grid solar system.
also heard from customers who require mobile UV disinfection for commercial and domestic applications,” Chamberlain said.
“We have been working in partnership with select customers to ensure these enhancements meet their requirements across the industry. Having
Beamex PG pressure generators
worked with an Australian developer it has allowed us to release this new range at a competitive market price whilst incorporating functionality which would ordinarily bring with it a greater price tag.” The 12V and 24V DC PLC controller can control UV-Guard’s UV systems up to a power of 40W. This means that recommended UV dose rates can be provided at flows of up to 60lpmby using the SLF, SLT and S-Series of systems. It can also control the storage tank headspace disinfection systems, the T-series. “We see this as the ideal disinfection solution for drinking water provision and commercial applications for our off the grid and mobile customers,” Chamberlain said. UV-Guard 02 9631 4900 www.uvguard.com.au
AMS AMS INSTRUMENTATION & CALIBRATION PTY LTD Unit 20, 51 Kalman drive Boronia VIC 3155 AUSTRALIA Phone: +61-3-9017 8225 Fax: +61-3-9729 9604 E-mail: sales@ams-ic.com.au Internet: www.ams-ic.com.au
Fast and reliable way to generate pressure To complement our integrated calibration solutions we have extended our range of calibration pumps. With precision and performance in mind, interchangeable across our range of pressure calibrators ranging from -0.95 to 700 bar the Beamex PG range are a fast and reliable way to generate pressure.
18 www.pacetoday.com.au JUNE 2015
www.beamex.com info@beamex.com
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DAF treatment and biogas
Biogas (methane) can be used to fuel boilers and heat processes.
DISSOLVED Air Flotation (DAF) is a tried and trusted treatment of industrial wastewater effluents produced by food, beverage and primary processing plants that are integral to the economies of many countries in Australasia, Asia, Africa, America and Europe. DAF’s great strengths as a primary treatment include relative simplicity in installation and proven cost-efficiency in separating oil and suspended solids from wastewater in diverse applications such as dairy, cereals and sugar cane. Compact and robust DAF systems reduce Chemical Oxygen Demand (COD) loading by the removal of high COD contaminants including fats, oils and greases, colour, organic matter and colloidal material. A reduction of up to 70-80 per cent COD and suspended solids can be achieved in some instances with chemical addition. As environmental and cost-efficiency demands increase on food, beverage and primary processing plants – and as such plants increasingly overlap with expanding urban areas – they face the twin pressures of achieving ever-higher wastewater discharge and waste disposal standards while also achieving greater cost efficiencies. Neighbouring communities these days won’t tolerate ground water pollution and air pollution in the form of smells form piles of rotting sludges and by-products. Shareholders, meanwhile, demand that any solution be ecologically sustainable and highly cost-efficient. These twin demands used to present a virtually indissoluble dilemma, a real
paradox, because better environmental technologies cost more, not less. But not anymore. Because proven DAF technologies can be very profitably combined with the latest anaerobic waste digestion technologies which not only extract very high levels (up to 90 per cent) of harmful COD contaminants from waste water streams and sludge by- products, but also convert them into profitable green energy. The sludge floated in the DAF process can be anaerobically digested thus eliminating a sludge dewatering and sludge disposal issue. Anaerobically digested sludge produces methane which can be used to fuel boilers. This biogas (methane) can be used to fuel boilers and heat processes, replacing costly and polluting fossil fuels. Or, if there is enough biogas, then it can be fed to generators for conversion to electricity that can be fed back to local grids and used to achieve carbon credits or pollution reduction credits. The UN has backed this method of achieving localised and highly efficient sources of electricity, which don’t suffer from the same energy losses as centralised electricity systems and do benefit their local communities. CST Wastewater technologies has installed DAF systems for numerous primary producers and food processors in Australasia over the last 20 years as well as advanced anaerobic digestion systems.
“ A real alternative to ultrasonics at an amazingly reasonable price.”
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
CST Wastewater Solutions 02 9427 1279 www.cstwastewater.com JUNE 2015 www.pacetoday.com.au 19
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AWARDS
Australia’s Women in Industry finalists
The 2015 Women in Industry Awards, a gathering of women going above and beyond in Australia’s industrial sectors, takes place in Sydney this month.
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ACE, Manufacturers’ Monthly, and Australian Mining are proud to announce that the finalists for the 2015 Women in Industry Awards have been selected from a list of impressive candidates. The only awards program of its kind to encompass mining, manufacturing and engineering, the 2015 Women in Industry Awards aims to recognise and reward the achievements of women working in the industrial sectors. The awards are all about celebrating women who are leading change in their chosen field and breaking down the barriers in what can often be male-dominated industries. The program seeks to single out and reward women who have created innovations, driven productivity, spearheaded change, and provided social and economic benefits through their fields. We would like to take this opportunity to thank the sponsors of the Women in Industry Awards – Pacific Merchandising (Platinum Sponsor),
20 www.pacetoday.com.au JUNE 2015
as well a MMD Australia, BOC Australia, and ABB Australia. Without their support the event would not be possible. With over 100 entries, it’s clear many employers were keen to have
their women recognised. We congratulate each and every finalist and look forward to seeing you all at the awards dinner. It all takes place on 25the June at the Ivy Ballroom, Sydney.
Last year’s inaugural awards night attracted more than 150 attendees.
BDM of the Year
Excellence in Engineering
Excellence in Mining
The judges are looking for an exceptional female business development manager working in any Australian industrial sector.
This award is open to all females working within the engineering industry. Judges will be looking for personal achievement and a meaningful contribution to the industry in a manner that sets them apart.
This award is open to all females working within the mining industry. Judges will be looking for personal achievement and a meaningful contribution to the industry in a manner that sets them apart.
The finalists Carly Bradshaw – Business Development and Operations Manager, Australian Dust Control Emma Cook – Business Development Manager, Agility Project Logistics Sandra Taylor – Tender Manager I&R East, Lend Lease Nicolette Hinson – General Manager Business Development and Strategy, Elgas Carrie Hartford – Senior Engineer, Jenike & Johanson
The finalists Cara Ryan – Office Manager, Building Performance Centre, Schneider Electric Christine Charles – Head of Space Plasma, Power and Propulsion Division, The Australian National University Claire Bianco – Engineering Supervisor, Cecil Park Plant, CSR Limited Hayley McIver – Senior Process Engineer, Ausenco
The finalists Kathy Zunica – Senior Geologist, AMC Consultants Maria Joyce – General Manager, MEC Mining Stephanie Hardy – Environmental Advisor, Monadelphous KT Pipelines Gail Clamp – Specialist Mine Management, Rio Tinto Coal Australia
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AWARDS
Excellence in Manufacturing This award is open to all females working within the manufacturing industry. Judges will be looking for personal achievement and a meaningful contribution to the industry in a manner that sets them apart. The finalists Christine Morris – HR Director, Joy Global Australia Michelle Vince – Group Range Development Manager, Blundstone Group Svetlana Zatsepin – Managing Director, Coolon LED Lighting Colly Galbiati – Managing Director, Soma Organics Kamini Wijekulasuriya – Manufacturing Manager, Western Sydney Service Centre, Bluescope
Rising Star Award The Rising Star Award is open to all females who are in their first five years of working within their industry. Judges will be looking for personal achievement and a meaningful contribution to the industry in a manner that sets them apart.
Industry Advocacy
Social Leader
Mentor of the Year
This award recognises women who have worked tirelessly to improve the image of their industry in the eyes of the public. The judges will be looking for involvement in specific programs or initiatives aimed at promoting their industry. Furthermore, the panel will also look at nominees who liaised closely with industry organisations to create better outcomes for those working in the sector on a policy level.
Community work is one of the distinguishing and admirable features of our industry. This award calls for nominations from women who have completed significant initiatives that have delivered a positive contribution to the community, or provided a positive social benefit over the past 12 months.
This award recognises talented managers within organisations who have actively and successfully shaped the careers of others within the mining, engineering, manufacturing and process control and construction industries. Any team leader is eligible for this award.
The finalists Irina Lindquist – Healthcare Solution Architect, Schneider Electric Carli Hobbs – General Manager, Gladstone Engineering Alliance Christine Katic – Operations Manager, BOC Limited Elizabeth Lewis-Gray – Chairman, Austmine Jill Follington – Executive (founding) Director, Industry Mid North Coast Kym Clarke – Founder and Director, She’s Empowered Suzanne Daubney – Managing Director, Bannister Downs Dairy
The finalists Teagan Dowler – Founder, The Blue Collared Woman Sue Webster – Executive Officer, Agribusiness Gippsland Jill Follington – Executive Director, Industry Mid North Coast Samantha Kerr – SCADA, COMMS & Protection Implementation Engineer, Energex Nicole Borkowsky – Associate Director, CDIF Group
Employer of the Year This award will go to the employer which has best demonstrated its commitment to the advancement of women in the workforce. This company has policies in place which are intended to allow the female members of its workforce to fulfil their potential and lead a balanced and productive life.
The finalists Kate Francis – Civil Engineer, Hyder Consulting Kate Macfarlane – Product Manager, BOC Limited Sally Mayberry – Environmental Advisor, Origin Energy Rachel Hogan – ABB Graduate Program, ABB Australia
The finalists Independent Racking Inspections & Audits Cablex
The finalists Ashlea Walley – VTEC Mentor/ DSG Program Coordinator, Wirrpanda Foundation Christine Cotton – Regional General Manager, Tcyo Fire & Security Simon Bradwell – Managing Director, ebm-papst A&NZ Pty Ltd Vanessa Sewell-Rosenberg – Talent & Organisation Development Manager, BOC
Marketing / Communications Our industries are home to some of the biggest corporations in the country and thus some of the most creative marketing departments. This award will go to a woman who has spearheaded a marketing campaign for a company, organisation, or association. The finalists Sally Durrant – Country Communications Manager, ABB Australia Rosalinda Willcox – Marketing Communications Specialist, BOC Limited Natalie Chapman – Corporate Communications Manager, Alkane Resources
Essential process safety training from IChemE Layer of Protection Analysis (LOPA)
HAZOP Study for Team Leaders & Team Members
15-16 June, Melbourne www.icheme.org/lopamel
7-9 July, Melbourne www.icheme.org/hazopmel
Process Safety Awareness
Engery Cost Reduction
23-24 June, Perth www.icheme.org/psaaus
4 August, Brisbane www.icheme.org/energyaus
Heat Integration
Process Safety & the Board
30 June - 2 July, Melbourne www.icheme.org/heatint
5 August, Melbourne www.icheme.org/psb
To register and to find out how these courses can be run in-house, email austcourses@icheme.org or call 03 9642 4494
JUNE 2015 www.pacetoday.com.au 21
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OPERATIONS
PLANTS & REFINERIES
Operation and control of flares Flaring is critical to the operation of chemical plants, petrochemical plants and refineries. Amin Almasi investigates the factors involved in operating flares safely and effectively.
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LARING is a combustion control process for chemicals, flammable gases and hydrocarbons in which the gases are piped to a remote, usually elevated, location and burned in an open flame in the open air using a specially designed burner tip (often flare stack tip), auxiliary fuel, and steam or air to promote mixing for nearly complete destruction of such gases. A flare is a critical mechanical component of a complete system design intended for the safe, reliable and efficient discharge and combustion of hydrocarbons and chemical from pressure-relieving and vapordepressurising systems. Being critical to the safety of an operating plant or facility, a flare should be continuously available with high reliability and capable of its intended performance through all operating-plant emergency conditions, including a site-wide general power failure or whole plant emergency trip. The flare and related mechanical components should be designed to operate and properly perform for the specified service conditions for an overhaul-to-overhaul period, say 5-7 years, without the need for an outage of the operating facility. If a flare is failed (for instance, because of a tip failure), whole systems that reply on it for protection should usually be tripped for some days (or even a week or more) for the flare repair, which can result in considerable financial losses.
Practicalities Flares can be used to control waste gas streams, and can handle fluctuations in gas concentration, flow-rate, heating value, and inert content. Flaring is appropriate for continuous, batch, and variable flow vent and relief stream applications. 22 www.pacetoday.com.au JUNE 2015
The majority of chemical plants, petrochemical plants and refineries have existing flare systems designed to relieve emergency process upsets that require release of large volumes of gas. These large diameter flares designed to handle emergency releases, can also be used to control vent streams from various process operations. Consideration of vent and relief stream flow-rates and available pressures should be given for a flare design. Normally, emergency relief flare systems are operated at a small percentage of total capacity (total capacity is supposed to be for total plant shutdown) and at negligible pressure. To consider the effect of controlling an additional vent stream, the maximum gas velocity, system pressure, and ground level heat radiation during an emergency release should be evaluated. Other considerations should also be respected such as maximum gas velocity limits or ground level heat radiation limits for flare system and flare stack location, height and details. To ensure an adequate air supply and good mixing, some flare systems inject steam into the combustion zone to promote turbulence for mixing and to induce air into the flame.
Operation and design The flammability limits of flared gases influence ignition stability and flame extinction. The “stoichiometric” composition is a chemically correct mix of air and flammable gas capable of perfect combustion with no unused fuel or air. The flammability limits are defined as the “stoichiometric” composition limits (maximum and minimum) of an oxygen-fuel mixture that will burn indefinitely at given conditions of temperature and pressure without further ignition.
When flammability limits are narrow, the interior of the flame may have insufficient air for the mixture to burn. Gas fuels, with wide limits of flammability are therefore easier to combust. Lighter gases usually tend to burn better. In addition to burner tip design, the gas density also directly affects the minimum purge gas required to prevent flashback, with lighter gases requiring more purge. Poor mixing at the flare tip is the primary cause of flare smoking when burning a given material or gas. Gas streams with high carbonto-hydrogen mole ratio (say greater than “0.34”) have a greater tendency to smoke and require better mixing for smokeless flaring. For this reason one generic steam-to-gas (gas being flared) ratio is not necessarily appropriate for all vent and relief streams. The required steam rate is dependent on the carbon to hydrogen ratio of the gas being flared. A high ratio requires more steam to prevent a smoking flare. The flare piping is designed to minimize pressure drop. Ducting is not used as it is more prone to air leaks. Valves should be kept to an absolute minimum, usually no valve is allowed expect one or two check valves in whole flare system. Piping layout is designed to avoid any potential dead legs and liquid traps. The piping is equipped for purging so that explosive mixtures do not occur in the flare system either on start-up or during operation. An important consideration in the material selection of flare and piping design is the possibility of low temperatures as the result of relief and blow-out of high pressure gases. For instance, as a very rough indication, in a unit with gas pressure above 90 Barg,
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OPERATIONS
it could be expected that some low temperatures be achieved in case of blowout or relief. Different scenarios should be established and simulated to find the lowest possible temperature. High pressure gas inventories if assumed at an ambient low temperature (say between 2°C and 10°C) can produce low temperatures of around -30°C to -50°C in flare piping. A flare system design temperature of -50°C or -60°C is not be unusual for a high pressure facility. Liquids that may be in the vent stream gas or that may condense out in the collection header and transfer lines are removed by a “knockout drum�. The knockout drum is typically either a horizontal or vertical vessel located close to the base of the flare stack. Some traditional flare designs used a vertical vessel located inside the base of the flare stack as knockout drum. Liquid in the flare stream can ex-
tinguish the flame or cause irregular combustion and smoking. In addition, flaring liquids can generate a spray of burning chemicals that could reach group level and create a safety hazard. For a flare system designed to handle emergency process upsets, a knockout drum should be sized for worst case conditions (for instance, total plant shutdown) and it is usually quite large.
Flare Control Flare system control can be completely automated or completely manual. Components of a flare system which can be controlled automatically include the auxiliary gas, the ignition system and steam injection (if steam is used). Fuel gas consumption can be minimized by continuously measuring the vent gas flow rate, its heat content and automatically adjusting the amount of auxiliary fuel to
Vent and relief stream flow-rates need to be taken into account. maintain the required minimum total gas. Automatic ignition panels sense the presence of a flame with either visual or thermal sensors and reignite the pilots when flameouts occur. Automatic control, based on flare gas flow, flame radiation or other methods such as observing the flare by camera or thermal imaging, is a good recommendation for modern flares. Even the steam flow (for steam injected flares) can be controlled in this way to maintain smokeless operation, which can give a faster response to the need for
steam and a better adjustment of the quantity required. To optimise steam usage infrared sensors are also available that sense flare flame characteristics and adjust the steam flow-rate automatically to maintain smokeless operation. Steam consumption can be properly minimised by controlling flow based on vent gas flow-rate or visual smoke monitors. [Amin Almasi is an Australia-based rotating equipment consultant.]
Connection to a variety of controllers Fast supply and bridging of the auxiliary voltage Reliable and unambiguous wiring
TERMSERIES The All-rounder Relay modules and solid-state relays with single and dual CO contacts from 6 mm width, with screw and tension-clamp connections. High-quality housing design with clear legible printing, illuminated ejector lever with high luminance and a safe VZLWFKLQJ PRGXOH UHOHDVH DV ZHOO DV XQLTXH DQG YHUVDWLOH FURVV FRQQHFWLYLW\ 1RZ DV D 3/& ,QWHUIDFH VROXWLRQ LQ SUH FRQĂ€JXUHG cabling and I/O block assemblies to manufacturers Rockwell Automation, Siemens, Omron and Schneider Electric ... Let‘s connect. www.weidmuller.com.au
JUNE 2015 www.pacetoday.com.au 23
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SPONSORED CONTENT
OPTIMISING MANUFACTURING PROCESSES IN THE STEEL INDUSTRY When it comes to achieving climate protection objectives or making fundamental improvements to operational performance, there are many aspects to analyse and evaluate. The approaches to this are particularly wide-ranging within the manufacturing industry.
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T’S not simply a question of reducing emissions. The efficient use of energy, materials and substances, water consumption, increasing waste and wastewater, and stresses on the ground all provide scope for economic opportunities. When it comes to maintaining high levels of product quality, modern measuring technology goes even further. The opportunities to strengthen individual positions can even be found in the steel industry. SICK’s intelligent sensors provide support at various measuring points in a wide range of production processes, so let’s take a moment to look at these in more detail.
Optimised melting processes reduce costs Electric arc furnaces (EAF) use powerful electric arcs used to melt down steel scrap, producing a range of basic construction alloys right through to special alloyed steel. The melting process begins at room temperature. The furnace is predominantly heated with electrical energy via electrodes, although limestone, powder activated carbon, lump coal, oxygen, natural gas or oil are also used in the melting process. In these cases, it is crucial to monitor the exhaust gas emissions. CO, CO2, O2, H2O, and H2 all provide information not only about the melting process, but also the efficiency with which the materials are being used. Take oxygen, for example: high oxygen content indicates that the flow of unwanted ambient air in the furnace or exhaust gas system is too high. This in turn causes the electrical energy consumption and use of coal, oxygen, or limestone to increase. If the CO content is too high, this suggests that too much coal or too little oxygen is being supplied. It’s the successful interplay between each step that makes all the difference. Once that’s been established, production costs can start to drop while productivity increases. To keep the climate footprint on an even keel, carbon dioxide emissions have to be kept to a minimum.
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All in all, it is fair to say that exhaust gas analyses on electric arc furnaces optimise the melting process. SICK takes measurements by using hot and cold extraction technologies.
Sensor solutions avoid the production of scrap in rolling mills Hot billets or slabs are used in rolling mills not only to form rods, wires, brackets or sections, but also metal sheets or plates. The quality of the products is always paramount – as well as the precise lengths specified by the customer or depending on the next step of the process. If the rods are too short, they’re scrap. If they are too long, they have to be processed further. Even the section that gets cut off, it goes to scrap. This is a costly piece of waste, as heat energy, working time and raw materials have all been “processed” at various stages along the way. With SICK sensor technology, this waste can be kept to a minimum, as photoelectric sensors, encoders, and other devices are put into place to suit the respective application. Laser scanners position slabs, for example, to minimise damage incurred in the flow path, while distance sensors measure the thickness of coils, the diameter of blocks, and even determine the length of cut sections. All of these devices work together quickly and
accurately to keep the entire process under control and thereby improve the level of cutting precision.
Sensors optimise electrical energy consumption in exhaust gas systems Exhaust gas systems are among the biggest energy guzzlers found in steel plants. Many of these systems are considerably older than the actual steel production facilities themselves and are therefore extremely limited in terms of their monitoring capacity. This leads to the situation in which the exhaust gas systems always have to run at full blast for the steel production process to function properly. The time, place, and level of extraction has to be determined and monitored around the clock, and the required level of exhaust gas is controlled by means of dampers and/ or fans. The energy consumption must be monitored and kept to a minimum without affecting the performance of the entire system. For this to be possible, the measuring technology in use has to be absolutely perfect. The FLOWSIC100 takes accurate flow rate measurements, which enables optimum control of exhaust dampers and fans. It is a rugged device that creates no drop in pressure within the conduit system. Multi-turn or single turn absolute encoders and incremental encoders are responsible for taking speed measurements for monitoring and controlling the main fans. This requires the use of technology with the highest levels of up time that is not only simple and stable, but also precise. The combination of both measurements optimises electrical energy consumption in exhaust gas systems and provides the finishing touch when it comes to process optimisation. SICK Pty Ltd 1800 334 802 www.sick.com.au
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OPTIMIZING THE MANUFACTURING PROCESSES IN THE STEEL INDUSTRY.
Intelligent sensors are needed at many points in the production, processing, transport and storage of metals and their raw materials. Sensors ensure efficient and safe production and trouble-free processing. SICK’s knowledgeable experts possess skills and expertise in a variety of fields: positioning of cranes, monitoring machine parts and materials, measuring material flow and level in silos and on conveyor belts, monitoring values for process control and securing dangerous areas. These are just a few of the wide range of applications that are solved using SICK sensors. For more information please visit www.sick.com.au or call 1300 405 807.
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NEW PRODUCTS
Software aiming for operational efficiency ASPENTECH recently released aspenONE Engineering and aspenONE Manufacturing and Supply Chain Version 8.8 software. Developed for firms in the oil, gas, chemicals, engineering, mining and construction, and other process industries, the software features userfriendly, streamlined workflow innovations. Fully integrated cost estimation, energy optimisation, and Heat Exchanger Design and Rating (EDR) technology brings key information to the process simulation environment. This allows faster and more accurate optimal design selection earlier in the conceptual engineering phase. Relief load calculation enhancements for heat exchanger tube rupture, fire emergency and control valve failure, expand relief sizing and safety modelling capabilities. The time to conduct pressure relief analysis is generally reduced by 50 per cent. With the addition of the Cubic-PlusAssociation (CPA) fluid property package, V8.8 software more effectively models methanol behaviour to accurately predict hydrate formation, improving flow assurance in pipelines and meeting environmental regulations. These
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enhancements lower operating costs. New Naphtha Hydrotreating and Alkylation models create a complete refinery reactor and assay management suite from within Aspen HYSYS Petroleum Refining. For the first time AspenTech offers a complete suite of refinery reactor models. The resulting flexibility means all process units can be accurately modelled and optimised, supporting planning for maximum profits. Polymers can be treated as solids below their melting points in Aspen Plus, allowing for accurate upstream and downstream modelling of solids production, including dewatering and drying. The ability to model polymers as solids results in reduced energy costs. The new Smart Tune technology in Aspen DMC3 enables users to quickly adapt to changing economic scenarios. It lowers the barrier to controller design and maintenance by providing more insight into controller strategy, and allows more users to set up and periodically reconfigure the optimiser more frequently with reduced workflow complexity. The New Campaign Manager in Aspen Plant Scheduler enables speedy creation and
The software is intended to improve safety and boost operational productivity. scheduling of an ideal production sequence or product wheel. Proven sequencing algorithms further optimise grade transitions to reduce offspec production and enhance asset utilisation. Aspen Technology Australia 03 9869 7120 www.aspentech.com
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Email your product news to editor@pacetoday.com.au
Booth A16, Hall 11.1
Electronic starter AUTOMATED Control and FEAS have released the Softstarter SAK31, an electronic starter for three phase AC squirrel cage motors of up to 3KW rating. Featuring low noise during start up, adjustable run-up time and variable startThe electronic starter ing torque, the electronic starter is designed is suitable for use in to reduce burden on the supply system and to improve motor reliability. tropical climates. Completely resin embedded within an industrial grade plastic housing, the electronic starter is self-cooling and has been designed to withstand harsh conditions. Installation is simply done via the use of DIN rail or by wall mounting. Further features include adjustable run-up time as well as adjustable starting torque. It has an operating temperature range of -20°C / +70°C and, because it is epoxy resin casted, it is suitable for use in the tropics. It comes with integrated relay with potential-free change-over contacts. • Input voltage (VAC): 3 x 400 VAC / 3 x 440 VAC (without N) • Output current: 8.5 Amp. • Power: max: 3.5 kW Automated Control 02 4722 4568 www.automatedcontrol.com.au
OTDC switch disconnectors ABB has introduced its range of OTDC switch disconnectors for DC applications up to 1,500A. The OTDC portfolio now includes solutions for installations with the most special requirements such as 1,500V DC voltages, multi-circuit switching and combined load outputs above 800 A. With these new products ABB is bringing the benefits of compactness, safe DC switching and low power losses of the OTDC products to the photovoltaic applications with higher amperages. The disconnect switches are ideal for disconnecting a solar inverter from the DC side and can be used in combiner boxes for switching of individu al PV arrays. The OTDC switch disconnectors have been designed to support the solar industry’s path towards higher voltages and, most importantly, greater efficiency. Additionally, the traditional 1000V DC PV disconnects have been expanded to now cover simultaneous switching of three DC circuits up to 500 amperes. For installations with more than one circuit, OTDC allows control of two or three circuits simultaneously,
FLUXUS
®
Clamp-On Ultrasonic Flow Measurement of Gases and Liquids p Highly accurate and reliable bidirectional flow measurement over a wide turndown ratio p Engineered and approved for use in hazardous areas (ATEX, IECEx Zone 1, FM Class I, Div. 1) p SIL2 capable and developed for operation in safety integrated systems (SIS) p Highest cost-effectiveness: - No pipe works - No process shut-downs - Virtually maintenance-free
The switch disconnectors are designed to be used in the solar industry. with only one switch instead of two or three separate ones. In some cases, the current levels in some of the largest main inverters may be higher than what OTDC range nominally covers. However, with the existing OTDC switches and ABB connection kits, it is possible to use a tested solution to create outputs of up to 1500 A (IEC) and 800 A (UL). ABB Australia 08 9412 1095 www.abbaustralia.com.au
p Zero point stable, drift free and independent of pipe dimensions, material, pressurization and the medium flowing inside (calibration traceable to national standards)
Oil- & Gas Exploration and Processing | Refineries (up to 400 °C and beyond) | Oil- & Gas Storage and Distribution | Chemical Industry
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NEW PRODUCTS
Inductive miniature sensors TURCK has added the Q4.7 series of rectangular inductive sensors to its range of miniature sensors. The miniature sensors in the new design (16mm x 8mm x 4.7mm) have been specially developed for applications in which they have to be fully embedded in metal, such as in the stamping and metal forming industry. These kinds of applications not only require robust sensors with large switching distances, but also very small housings so as The sensor is to reduce the amount of surIP67 rated. rounding metal to be removed for the recesses. The Q4.7 meets all the requirements mentioned with a two millimetre sensing range, a robust metal housing, a highly flexible two metre connection cable with an oil-resistant sheath and the capability of being fully flush mounted. TURCK has managed to house the status LED in the active face so that this, in contrast to side mounted LED sensors, stays visible even when fully flush mounted. In order to meet a wide variety of application conditions, the Q4.7 has a temperature range from 0 to 85° Celsius and is IP67 rated. Turck 1300 132 566 www.turck.com.au
MPC software
EtherCAT
Bus
EtherCAT
Terminals
Terminals
Box
(IP 20)
(IP 20)
(IP 67)
Servomotor 50 V, 4 A
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50 V, 4 A, OCT
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Stepper motor 24 V, 1.5 A
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50 V, 5 A
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24 V, 1 A
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50 V, 3.5 A
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DC motor
50 V, 5 A
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ROCKWELL Automation’s Pavilion8 Model Predictive Control (MPC) software now delivers a more userfriendly configuration environment, step-by-step prompts, warning diagnostics and flexible work flows to simplify building, maintaining and adjusting complex process models. Pavilion8 MPC v5.0 software remains control system independent, but integrates with the PlantPAx process automation system from Rockwell Automation and includes the following four key enhancements: Windows-based configuration and support – An improved overall user experience for expert and inexperienced users alike with updated, Windows-based solution builder tools. Multivariable run-time controller –The robust run-time controller has been updated to allow users to add new predictive disturbance measures in half the time as the previous version, and easily compare differences in MPC application versions.
Continuous controller monitoring – Users can now configure their process models with specific metrics for production, quality, energy usage and other factors. Modern browsers and operating system support –This includes support for newer browsers like Internet Explorer 11 and operating systems, such as Windows 2012. Pavilion8 software is also the first platform to combine empirical and first principle models into a single composite model. With proven return on investment when applied to a wide range of industries, continuous processes and equipment, Pavilion8 software uses an unrestrictive and robust configuration approach. This allows it to adapt to changing business needs and to flexibly meet simple linear to the most challenging nonlinear processes. Rockwell Automation 03 9757 1111 www.rockwellautomation.com
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THE LAST WORD
PLANT MANAGEMENT SOFTWARE
The benefits of simulation software Australian companies operating within the Metals, Mineral and Mining (MMM) sector often focus on strategies to adapt to changing circumstances while the opportunity to manage and optimise internal operations isn’t fully explored.
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he external framework of MMM is unpredictable and subject to many volatile external factors like low commodity prices, the cyclical nature of ore prices and numerous political challenges. These challenges have now been hindered with internal issues such as plants operating at less than optimised conditions and a new generation of workers that do not remain in one job very long, making training more critical. Over the next few years, environmental sustainability, rebased globalisation and resource security will continue to shape and drive the direction of the industry. In order to remain successful, companies must maximise returns from existing operations by improving current productivity and efficiencies, not necessarily by increasing production volumes.
Dynamic training
The pre-testing of control logic in a dynamic simulation environment can reduce commissioning time by several days and sometimes even weeks. Virtual stimulation software can augment the dynamic model to design, test and perform system checkout prior to start-up. Because all functions are executed within a dynamic environment, it can also be used as a training tool. Regardless of mining operation complexity, it is important to fully train operators to safely and efficiently operate the process. However, workers in the mining industries have a high turnover rate which means companies need to focus on new, time-efficient training methods, such as Operator Training Simulators (OTS). Reducing the time it takes to properly train an operator reduces costs that can be allocated to other parts of the business. Progressing internal resources such as asset management from reactive, through preventive and all the way to predictive maintenance can cut expenditure dramatically. By doing this the MMM sector can simultaneously 30 www.pacetoday.com.au JUNE 2015
invest more in other projects to safeguard from fluctuating external factors and aiding in the training and retention of skilled workers.
Real time optimisation
Basic controls are designed and built with the process itself, to facilitate basic operation, control and automation requirements. Distributed control systems (DCS) or programmable logic controller (PLC) systems contain virtual simulations which are built on algorithms and communication infrastructure of industry control processors. These save time and resources by providing high-quality operator training and accurately analysing and troubleshooting control system response and performance. Real-time optimisation is the final step and begins with the instant measurement of throughput, energy and metallurgical accounting. With predictive software, KPIs at each consumption, production, transfer, import or export point can be quantified and reported. In some markets the
correct use of this intelligence has been shown to predict impending events which can deliver 3-6% average reduction in energy consumption and critical production improvements. This data also can be used to reduce unplanned outages to less than 1% and increase utilisation by more than 2%. Optimising internal resources to reach the final stage of operations management is useful to stabilise expenditure and negate volatile market swings and soaring energy costs. Although effective asset management and operations management can be honed separately it is their convergence that is key to optimising internal operations. A single set of integrated software tools across the entire supply chain – from mills, pyro processes, hydrometallurgy, bulk delivery to port – is necessary for convergence of the two.
Simulating reality
A network of integrated software tools is vital to ensure internal resources of MMM companies are properly managed with a continuous view of their assets
along the entire supply chain. Simulators can provide an off-line or on-line virtual environment which mimics the process plants and all its function, thus enabling scalability studies, control architecture design and validation, process optimisation, control systems tuning, operator training and ‘what if’ scenarios. Maintenance teams can also use these simulators to test system checkout for start-up, conduct operator training and safely operate the facility. An operator training simulator (OTS) integrated with a plant’s real control system graphical interface also allows an operator trainee to become familiar with all aspects of operating a facility from a familiar yet totally risk-free environment. Operators can practice plant operation under normal circumstances, as well as instances where certain variables are changed, a mechanical breakdown occurs or a new standard operating procedure is implemented. Production teams, on the other hand, use the validated dynamic model to advance control system design and troubleshooting, utilising control systems as required. An example of this software is SimSci from Schneider Electric which provides operators and trainees with a single continuous view of assets along the entire supply chain – from extraction to delivery. This empowers operators to plan, manage and optimise performance. This fullyintegrated model provides a common interface for driving simulation, training and optimisation initiatives within a facility. To achieve this, a considered approach to asset management, operations management and technology must be adopted. This converged approach creates the solid internal base necessary for companies to operate and thrive in uncertain environments. Schneider Electric 1300 369 233 www.schneider-electric.com.au
TICKETS NOW ON SALE! Celebrating its 12th year, the 2015 PACE Zenith Awards ceremony will take place on Thursday 11th June in Sydney. This is the industry’s night of nights, where we recognise and reward companies and individuals who have contributed to Australia’s Process and Control Engineering Industry. DATE: Thursday 11th June 2015 TIME: 6.30pm pre dinner drinks for a 7:00pm start VENUE: Four Seasons Hotel, Sydney TICKETS: $150 + GST per person or $1,200 + GST for a table of 10 Tickets include a 3 course dinner and beverages
Categories for the 2015 PACE Zenith Awards include: • • • • • •
Manufacturing Best fieldbus implementation Food and beverage Lifetime achievement Machine builder Mining and minerals processing
• • • • • •
Oil and gas Power and energy management Water and wastewater Young achiever Project of the year Transport, power and infrastructure
To book your tickets to the PACE Zenith Awards dinner please contact carlyp@fst.net.au or phone 02 9376 3235
For more information visit www.paceawards.com.au PROUDLY SPONSORED BY
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Event response can’t be left to chance. My operators need the confidence that they are taking the right action – every time.
YOU CAN DO THAT Make every operator your best operator. Emerson helps operators meet production goals by ensuring work is done accurately and consistently. Syncade Suite combines document, equipment, and materials management into electronic work procedures to create an optimised manufacturing environment. By implementing Syncade as your MES, you integrate plant-floor data with procedural processes to help your operators do their best work. Visit www.EmersonProcess.com/Syncade to learn more.
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2015 Emerson Electric Co.
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