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

PACE.MAR12.PG001.pdf

MARCH 2012

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VOL.65 NO.2

Energy Management Energy efficiency begins with conceptual equipment and good process design. Viewpoint 7

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Four components, one system: New Automation Technology. Motion Servo Drives Servomotors

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www.beckhoff.com.au Setting standards worldwide: PC- and EtherCAT-based control solutions from Beckhoff. As renowned specialists for open automation systems, Beckhoff offers components for IPC, I/O, motion and automation applications that can operate individually or integrated as a precisely adapted control system. New Automation Technology from Beckhoff represents versatile automation solutions that are used in a wide range of applications worldwide. The growing presence of Beckhoff in more than 70 countries ensures consistent support around the globe. IPC I/O Motion Automation

Software PLC Software NC/CNC Safety

PACE.MAR12.PG003.pdf

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CONTENTS

IN THIS ISSUE PROCESS & CONTROL ENGINEERING

Published monthly by Reed Business Information Pty Ltd

Tower 2, 475 Victoria Avenue Chatswood NSW 2067 Locked Bag 2999 Chatswood DC NSW 2067 Tel: (02) 9422 2999 Fax: (02) 9422 2977 ABN 80 132 719 861 Publisher: Michelle Graves Email: michelle.graves@reedbusiness.com.au

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

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

16-17 Technology Update 12

Networks 18

Chemicals 26

Plug-n-play installation Extensive diagnostic data is possible through today’s advanced pH sensors incorporating Smart technology.

Industrial Ethernet A structured and total lifecycle approach to Industrial Ethernet will improve network performance and reliability.

Automation application A nitric acid plant implements an integrated technology solution on a single platform for all process automation applications.

Industry Leaders 16

Mining 22

IICA News & Views 30

Outlook 2012 The sponsors of the 2012 PACE Zenith Awards offer insights into the industry and discuss trends for the year.

Curragh Mine upgrade A re-engineered solution ensured that long term functionality could be maintained for the life of the mine.

IC&A’s contribution Are our politicians aware of the IC&A sector’s contributions to our country’s wealth creation potential?

CUSTOMER SERVICE: 1300 360 126

ON THE COVER MARCH 2012

VOL.65 NO.2

Energy Management Energy efficiency begins with conceptual equipment and good process design.

Viewpoint 7

PLM Directions 2012 Successful product development requires management of complexity. Analysis 10

OFFICIAL MAGAZINE OF: E

IMAG

Unifying motion, automation, vision & communications Post Print Approved PP255003/00539

Average Net Distribution Period ending September ‘11 7,034

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and synchnonisation of servos is possible, via the EtherCAT machine network and distributed clocks. EtherCAT refresh is 100µs with less than 1µs jitter. Topologies are flexible, suiting remote I/O like Omron’s GRT1 I/O slices. Motion functions include linear and circular interpolation, electronic gearing and CAMS, and virtual axes. Automation is equally impressive, supporting maximum 2560 rack I/O. USB, EtherCAT and Ethernet/IP ports are built-in, plus CJ1W communications unit support. Omron Electronics 1300 766 766

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MARCH 2012 www.pacetoday.com.au 3

PACE.MAR12.PG004.pdf

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COMMENT

EDITOR’S MESSAGE

Are we an invisible industry? Kevin Gomez Editor

Next Issue

• Motors, Drives & Motion Control • Information Integration • Wireless Technology • Process Control in Food & Pharmaceuticals

indUStry analysts and the media tend to overuse the phrase ‘two-speed’ or even ‘three-speed’ to describe the Australian economy. We have been lulled into a false sense of security, naively believing that mining will keep us afloat while clueless politicians, aggressive unions and the high exchange rate wreck havoc with our industrial and food manufacturing sectors. it is with some dismay that i see the term ‘one-speed’ economy coming into use to describe our economy of the near future. to many observers, the commodities boom is starting to go bust and Australia is forecast

to join the rest of the developed world in the slow lane. in January, global steel output fell eight percent year on year. this has a major effect on the demand for coking coal and iron ore - essential inputs for steel manufacture and, incidentally, the country’s biggest commodity exports. Some analysts expect iron ore prices to halve in the next three years. if accurate, this has implications for the many companies in the instrumentation, control systems and automation (iC&A) industry that depend on the resources boom. Fortunately, the services and solutions offered by iC&A

vendors can often be transferred across industries. moreover, even if our commodities output does reduce, miners will strive to boost efficiency and cut costs. Automation and smart solutions will play a key role in these efforts. in this month’s iiCA

column, Brett Simpson stresses the breadth, scope and contribution of our industry. the diversity and reach into virtually every sector and application area makes iC&A a powerful beast. Albeit, a relatively invisible one. Simpson closes with this rather poignant question: Are Australian politicians of both persuasions aware of the importance of the iC&A sector’s contributions to our country’s wealth creation potential? As this issue of PACE goes to press, our leaders are locked in mortal combat. to the victor will go the spoils. the rest of us be damned. kevin.gomez@reedbusiness.com.au

OUTLOOK

Looking at the future for technology and business By Jim Pinto become an anachronism. Hierarchies social media is a hotbed of demographic StEVE Jobs said that the best way to will disappear and many teams will and psychographic insights; massive predict the future is to invent it. A few function without leaders. Asian middle-class; affluent people will like him may indeed be able to invent the best ideas may come from have second-residences in developing the future, but most of us must simply juniors, some outside the organisation countries; four winners - Amazon, react to it. it’s useful to think about altogether. more companies will engage netflix, Spotify and Pandora. what may happen in 5-10 years so that in “crowd sourcing” - piecing out jobs the UK Guardian comes up with its we can react, deploy resources and or even parts of jobs to whoever can and list of 2012 predictions: mobile wallets; develop products and services that anticwants to do them. free phones and messaging; Apple tV ipate change. take a look at Fortune’s Looking shorter term, my friend - i already spend $50/month watching guide to the future. Perry marshall comes up with predicthe latest movies whenever i wish, with A D _coming P A Cchanges E M E Twill 2 M R _ 1 2 . tions p d ffor 2012: P a gEurope, e 1 USA 2 4and / 0Asia 2 / 1 2 no , commercial 9 : 4 3 interruptions; AM the beAuncomi predict fortable for some. the term “boss” will will have major economic corrections; the death of commercial tV within a

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decade. As one begins to think about the further-out future - a century away some things become obvious. Here are some of my selections from a BBC News list: oceans will be farmed; Antarctica will be settled; single worldwide currency; only three languages in the world - English, Spanish and mandarin; marriage will be replaced by short-term (annual) contracts; there will be a world government; wars will be fought completely by remote-control. Jim@JimPinto.com

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NEWS

WIRELESS

Yokogawa pushes ahead with ISA100.11a devices YOKOGAWA is strengthening its position in the ISA100.11a compliant wireless arena with the release of three new field wireless system devices and enhanced wireless pressure and temperature transmitters. The first of these products is scheduled for release this month. The new wireless products can be used to construct large-scale plant networks, and complement Yokogawa products, expanding their capability. This is in line with Yokogawa’s “Grow” concept, which enables customers of both large and small plants to expand their plant wireless networks while making full use of existing assets. Yokogawa Managing Director, Australia & New Zealand, John Hewitt, says Yokogawa’s approach represents a new paradigm in allowing customers to easily, efficiently and cost-effectively expand plant networks with the same level of reliability and redundancy inherent in Yokogawa’s hardwired systems. “In July 2010, Yokogawa released the world’s first ISA100.11a compliant field wireless devices. As the industry’s support of the soon to be international ISA100.11a standard gains momentum, the number

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of ISA100.11a products is expected to increase and Yokogawa has been quick to embrace the new wireless paradigm instead of locking customers into proprietary legacy solutions,” said Hewitt. “We will continue to enhance interoperability for seamless connection with other companies’ products and develop sophisticated wireless control solutions for continuous processes. Our focus is on field wireless communications solutions based on the “Grow” concept. By making possible the expansion of wireless systems, educating users about wireless solutions, and improving convenience, we aim to help our customers grow their plant operations. “Yokogawa has put in place useful upgrade paths using the ISA100.11a wireless standard to provide more rapid and effective solutions without compromising on network integrity,” he added. inquiries@au.yokogawa.com

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PACE.MAR12.PG007.pdf

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OPINION

EFFICIENCY

Energy management Plants lack real-time performance information, writes Florian Güldner.

HILE we’ve seen many examples of good practices in energy saving and efficiency initiatives and hear much discussion about the merits of energy management systems (EMS), energy management currently lacks a formal framework that integrates the supply chain and plant life cycle issues with manufacturing operations and business functions. For example, while advanced control and real-time process optimisation solutions often include energy consumption as variables for optimisation, if the process units themselves were not designed to optimise energy efficiency, much opportunity for saving energy is

lost. Furthermore, automation suppliers are just now beginning to explore the potential energy savings that can be realized by integrating plant electrical control and process control systems. And enterprise solution suppliers have only recently begun to explore how their production management and enterprise asset management (EAM) solutions can be extended to help users measure and manage energy consumption. As a result, energy management and energy efficiency initiatives are often incomplete and insufficiently coordinated. This can be very costly for manufacturers, and will only increase as both energy costs and costs associated with carbon emissions rise. Here, we’ll

Automation suppliers are just beginning to explore the potential energy savings that can be realised by integrating plant electrical control and process control systems. explore briefly several different dimensions of energy management as they map against ARC Advisory Group’s three-dimensional, Collaborative

Manufacturing Model (CMM). Status quo of energy management in manufacturing. According to an ongoing ARC survey, many end users have implemented “homegrown” EMS solutions. Compared to commercial solutions based on industry standards, homegrown solutions tend to be more costly to support over time. Most homegrown solutions never grow beyond being point solutions. This situation is regrettable because energy is the second largest expense for industry and end users end up paying too much for their often-ineffective homegrown solutions. While many users in the discrete manufacturing industries have only just recently started to look closely at >

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OPINION

their energy bills, users in the energyintensive process industries have been scrutinising their energy costs for several decades. Most energy-intensive operations experience variability in energy consumption due to changing operating conditions, equipment degradation, fluctuating market demand and inefficient control strategies. Plants use more energy than necessary, yet are unable to improve efficiency because they lack real-time performance information. Energy management along the supply chain axis. Comprehensive energy management involves both sourcing and logistics. From a sourcing point of view, many companies now buy “green” and use Energy Star and other labels as a reference point for consumers. Sourcing raw materials also includes purchasing electricity and fuel. Whether they purchase or generate their own electricity and/or process steam, manufacturers need to balance short-term, mid-term, and long-term supply and demand to optimise energy consumption. The short term relates

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PACE.MAR12.PG009.pdf

to optimisation of the process, varying from real-time to horizons of a few hours. The middle term relates to taking production fluctuations and small equipment changes into account, while the long term relates to large fluctuations, such as created by plant revamps. Energy management along the life cycle axis. The ultimate energy efficiency of the production and energy generation processes begins with conceptual equipment and process design. Heat recovery and heat integration at the equipment-, plant-, and site-wide levels should be taken into account, along with product packaging and recycling. Energy-efficient equipment, such as variable speed drives and more efficient pumps and motors, plus more efficient lighting and HVAC in the production areas, can reduce energy consumption to a significant degree over the longterm plant life cycle. The trend in the process industries is toward high-yield, combined heat and power generation plants and the highly energy efficient production processes. In discrete and

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The ultimate energy efficiency of the production and energy generation processes begins with conceptual equipment and process design.

hybrid industries, rising energy prices also put pressure on variable costs and lead to new product designs that incorporate alternative raw materials that are less energy-intensive, or demand a less energy-intensive production process. Energy management along the business/automation axis. The most diverse and challenging aspects of energy management are in the business domain and in production execution. In the business domain, strategies are defined for global energy management. Here, EMS implementation depends on

corporate long-term investment decisions, ideally made in collaboration with plant management. In daily operations, energy usage should be monitored and, for complex processes, optimised in close to real time. In this domain, process operations and control are intimately connected. Most energy-intensive operations experience considerable variability in the consumption of energy due to changing operating conditions, equipment degradation, fluctuating market conditions, plus poorly tuned control loops, inappropriate control strategies and/or lack of process optimisation. When real-time information is not available, or if control applications are not easily maintainable or adaptable, plants use more energy than necessary. At the automation level, EMS remains a work in progress. Using PLCs to control power in individual energy-consuming devices, such as electric motors, is still in its infancy. At the enterprise or production management level, several suppliers offer solutions that enable manufacturers to

measure and monitor energy consumption in a real-time manner using realtime and other data collected from control and asset management systems. An adaptive framework needed. The different domains are intimately related: demand and supply balancing intersect with process life cycle improvements and maintenance. Efficient processes are more complex and require more complex control solutions. Investments in these solutions are costly and must be coordinated with longer-term initiatives. Excellent short-term process optimisation and energy management practices exist, but these may lack coordination with initiatives in other domains and on long-term time scales. Users need an adaptive implementation framework for energy management that coordinates initiatives in different domains across different time scales, with a strategy, a management system and competence centres for sharing best practices. [Florian G端eldner is an Analyst with ARC Advisory Group.] www.ARCweb.com

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OPINION

MANUFACTURING

PLM directions in 2012 Product lifecycle management will provide new opportunities, writes Rajiv Ghatikar.

USTRALIA’S process and engineering sector faces increased volatility in 2012, yet the demand to achieve greater efficiencies and cost savings have never been stronger or as necessary. Product lifecycle management (PLM) software provides opportunities in a new world of process engineering. Digital manufacturing software is revolutionising the way products are being produced throughout the industrialised world. Due to the widespread adoption of Computer-Aided Design (CAD), Computer-Aided Manufacturing (CAM), and ComputerAided Engineering (CAE) software tools, almost every product made today is modelled, tested and ‘produced’ in a virtual environment. As a result, product development time has been significantly reduced while product quality continues to rise. A key driver in this evolution has been PLM software and systems that harness the massive amounts of data involved. In today’s era of macro-economic uncertainty, manufacturing companies need to take advantage of the collaboration and visualisation capabilities both within and outside the extended enterprise: a process that PLM enables. Market demands for greater choice has led to unprecedented levels of complexity in production processes. Think of the complexity one major automotive OEM faced in meeting customer demands for a new pickup truck. Depending on where you are in the world, you can get it with one of three different engines. There are six trim styles, three cab configurations, nine wheel possibilities, eight tire options, five different radio choices, 18 seat options, 12 colours, three trim colours, and so on before you get to the ‘in car’ options and variations. There are literally millions of different buildable combinations and perhaps trillions of theoretical combinations. Yet it is only part of the complexity challenge. The product development process itself is complex too, involving

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that had a software issue. Using PLM, the company was able to trace the ECUs to an individual customer’s vehicle by the vehicle identification number (VIN) and do things like track every software component by vehicle program, series and variant of those programs. So if a customer’s vehicle was returned to the dealership with a specific concern that cannot be resolved at the dealership, the VIN could be used to retrieve the complete software bill of material for that vehicle using tools from the OEM’s customer service division. As a result, ECUs can usually be reprogrammed rather than replaced if there is a problem in the field, helping the company to avoid more than $100 million worth of module replacements over a three-year period. PLM provides Australia’s process and engineering sector with major opportunities to meet challenges ahead. In 2012 and beyond they can expect: ❏ Smarter decisions, better products Smarter application of PLM software will facilitate customers’ ability to turn their ideas into successful products and drive their business forward in an informed manner. PLM software enables smarter decisions that lead to better products. This in turn drives customers’ business, fuels their growth and sustains their margins.

By managing software as it would a mechanical component the PLM system makes it possible to quickly view and manage these dependencies.

hundreds of suppliers and partners scattered around the world. Added to that is the complexity of today’s design proc-

esses, where we see input from multiple domains - mechanical, electrical, electronic, software - along with different toolsets and sources of data. PLM software is being used to create an infrastructure to manage product and process complexity. A case study about this same automotive OEM reported that its 2007/2008 vehicles had an average of six million lines of code and that they were expecting about 10 million lines of code in 2010 models. This rapid expansion of software in vehicles was creating a problem with dealerships when it came time to replace or repair electronic control units (ECUs)

❏ Use of PLM software and systems

as a single source of product knowledge for data and processes across all domains including mechanical, electrical, and software To serve as a single source of knowledge, the PLM system must support all relevant product data - mechanical CAD data, ECAD data, software components and so on. With all of this information in one place - the PLM system - all product team members know where to find the information they need. Having a shared view of the overall product guides each domain in implementing its part of the product.

PACE.MAR12.PG011.pdf

❏ Use of PLM to communicate and

manage product requirements across domains Best-in-class process engineers work closely with customers to identify needs and problems, and then use that information to establish functional requirements that drive product development. Given the current level of product complexity, those requirements almost always involve more than one design domain and must cover intelligent mechatronics features. These features often result in added electronics, increased embedded software, and smart processes, resulting in requirements that must be communicated and managed. PLM provides product teams with visibility into each requirement, as well as the knowledge behind it. In addition, by supporting cross-domain systems definition, PLM makes it possible to understand how key characteristics such as performance and maintainability are affected by given requirements. PLM also enables the traceability of require-

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ments all the way to the product’s implementation. Traceability improves product quality by eliminating feature creep and incorrect implementation. ❏ Use of PLM for dependency

management across mechanical hardware and software components The advanced functionality in many of today’s products comes from embedded software and electronics. Although less expensive to innovate this way compared to the costs of adding new mechanical components, the growing role of software is challenging. All embedded software must be proven to function correctly, as well as to work flawlessly with the computers, wiring, sensors, actuators and other electro-mechanical content in every product configuration. Using a PLM system to manage embedded software is a way of capturing the complex interdependencies between software, computers, product configurations and other hardware that come together in each product configuration.

By managing software as it would a mechanical component, the PLM system makes it possible to quickly view and manage these dependencies. Another critical step in the software lifecycle is matching software ‘parts’ to their hardware counterparts. By establishing and tracking these associations across multiple product options and variants, a PLM system can help eliminate configuration errors and reduce warranty costs. PLM can also promote the management of all software documentation, specifications, test data, build processes, binaries and source code into unique software components. This association fosters efficient use of software searches, comparisons and reuse. ❏ Use of a PLM system to include

suppliers, partners, and vendors directly in your processes The complexity of the design chain has increased exponentially since companies started outsourcing more of their product development work and setting up their own operations in other coun-

tries. PLM’s value here is that it constitutes a single, virtual, integrated system that include suppliers, vendors, and partners directly in the product development processes. This has definite advantages for managing complexity, including the creation of a complete product definition that incorporates supplier data as part of the BOM. In addition, vendor management capabilities within a PLM system can keep track of pertinent vendor information including environmental compliance data. Successful products require intelligent management of complexity, in all its manifestations - huge numbers of product configurations, growing use of software and electronics, dispersed product teams and supply chains. With PLM’s ability to manage all of these factors, process engineers will continue to take advantage of its capabilities and provide companies with competitive advantages. [Rajiv Ghatikar is ASEAN Vice President & General Manager, Siemens PLM Software.] www.plm.automation.siemens.com

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IN FOCUS

Smart pH loops for plug-n-play instal l Extensive diagnostic data is possible through today’s advanced pH sensors with Smart technology that enables p calibration and installation time, writes Linda Meyers.

EW technology enhances pH sensors usage because of the Smart software that’s implemented in advanced pH sensors and instruments. Never before has it been so easy to calibrate, plug-n-play, and evaluate pH monitoring. Before the Smart technology emerged, the only way to calibrate the pH sensor was to carry all of the calibration equipment into the field. In many facilities, this meant carrying at least two buffer solution bottles, two beakers and one rinse bottle to the various installation sites. Then, the calibration was done on-site at a location closest to the sensor installation. So come rain or shine, sleet or snow, hot or cold

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weather conditions, the technician had to maintain the sensor in even the worst environmental conditions. Smart technology changes all that. Smart pH sensors have a memory which holds calibration information, so there is no need to carry equipment to field. The sensors can be calibrated in a controlled environment such as a laboratory or maintenance shop and the calibration information is uploaded into the sensor. The sensor can then be taken to the field and installed on-site or it can be stored on shelf (keeping sensors wetted) until it’s time to replace one in the field. Many of the sensors implemented with Smart technology also use a special cable-to-sensor VP connector system.

Using the Smart information that is stored in the sensor will help the user evaluate the state of the sensor’s health. This allows for plug-n-play capability so that the user can plug the pre-calibrated sensors into field equipment and the sensor is ready to measure. This is especially advantageous for facilities with remote locations or multiple installations. It also gives the

added benefit that the sensors can be rotated in and out of process as needed with minimal downtime. This quick and easy sensor exchange keeps the process up and running. Using the Smart information that is stored in the sensor will help the user evaluate the state of the sensor’s health. When operators understand how to interpret the basic information for the pH slope, glass impedance, reference offset, and reference impedance values, they gain a deeper understanding of how the information contained in the Smart software can prolong sensor life. The four main concepts for using the Smart sensor information during calibration are:

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tal lation reduce calibration time

nables plants to lower maintenance requirements and costs and decrease the risk of downtime while also reducing o Slope Trends, which normally

decrease over time o Glass Impedance Trends, which normally increase over time o Reference Offset Trends, which normally shift slowly over time o Reference Impedance Trends, which normally shift slowly over time

Membrane health

The pH sensor slope information indicates the health of the pH sensitive glass membrane. The slope naturally decreases as the sensor ages. It also will decrease faster with elevated temperatures. Viewing the slope trends information allows make A Dusers _ P to AC E Pinformed H O M A decisions. R_ 1 2 . p d f o Good sensors that can be confidently

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used have a slope value of 54 mV/pH to 59.16 mV/pH. o Bad sensors have a slope value of 48 to 50 mV/pH, which is too low and the sensor should be replaced. Glass impedance is another indicator of the pH glass health. Typical pH sensors have an impedance value of 50 to 200 MOhm; some speciality pH glass sensors used for higher temperatures have a maximum glass impedance value of 1,000 MOhm. Viewing the glass impedance information allows users to make good decisions about the glass health, and glass impedance values trending up to 600 - 1,200 MOhm may indicate one of the following issues: > o The glass is getting old due to

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IN FOCUS

high temperature exposure or normal aging; in this case, the sensor needs to be replaced soon. o The sensor is not immersed in the process liquid or buffer solution. o The glass is dirty and should be cleaned before installing it back into the process liquid.

Cracked glass

Glass impedance values of less than 10 MOhm identify cracked glass, excessive exposure to high temperatures, or a high impedance short in the sensor. In any of these scenarios, the sensor should be replaced. The reference offset indicates the health of the reference electrode. New sensors placed in pH 7 buffer solution will have an ideal output of 0 mV. An acceptable offset is 60 mV maximum. Viewing the reference offset trends allows the user to make informed decisions regarding sensor calibration or replacement. o AAreference lessNthan D _ P Aoffset C E of CO N O 60 V _mV 1 1 . pdf can be adjusted by standardising.

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1 1 / 1 0 / 1 1 ,

1 1 : 5 4

INTELLIGENCE: Smart pH sensors have a memory which holds calibration information so there is no need to carry equipment to the field. o A reference offset of 60 mV or higher

means that the reference electrode is spent or dirty. This indicates that it is time to replace or recharge the sensor. The reference impedance value is another indicator of the health of the reference electrode. The normal reference impedance value on a new pH sensor is between 10 and 60 kOhm. Viewing the reference impedance information allows the user to make good decisions about sensor maintenance and replacement. A high impedance value is 140+ kOhms and indicates one of the following: o The reference is coated from a dirty process liquid and needs to be cleaned. 14 www.pacetoday.com.au MARCH 2012

o The reference junction is clogged and

the sensor needs to be replaced.

o The reference electrolyte is depleted

and the sensor needs to be replaced. This extensive diagnostic data is possible through todayâ&#x20AC;&#x2122;s advanced pH sensors with Smart technology that enables plants to lower maintenance requirements and costs and decrease the risk of downtime, while also reducing calibration and installation time. [Linda Meyers is senior pH product manager, Emerson Process Management, Rosemount Analytical.] Rosemount Analytical 1300 55 3051 www.RosemountAnalytical.com

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Little on size, Large on performance Introducing the new L Series programmable controller

proven performance / global strength / cost effective solutions www.mitsubishielectric.com.au or call us on 02 9684 7777

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PACE ZENITH AWARDS 2012 SPONSORS

Introducing our 2012 sponsors Automotive & Manufacturing

Oil & Gas

Customers are demanding product and technology that is both powerful and easy to handle. This is in part due to the skilled labour shortage. There is definitely a demand for technologically advanced products that are very simple to handle, as it doesn’t necessarily require a skilled worker to set up and use. We offer products that meet these specifications, simple to set up with great price performance ratios. Customers are seeking efficiency gains with their machinery by investing in real time maintenance. This reduces the need for costly machine down time as a result of breakdowns. “We offer products that highlight early detection of damage, offering machine protection,” says Dave Delany, Managing Director, ifm efector. Detection of unbalance, monitoring of overall vibration and bearing condition and trend analysis with integrated history function and condition counters are possible. This increases machine availability, secures quality and makes maintenance planable. ifm invests significantly in research and design, and in 2012 this will create new opportunities in the market for us. For 40 years the company has been researching, developing and producing products and technology with the aim of optimising technical processes. As a company focused on innovation and increasing the efficiency of your applications, we are constantly releasing new products to market and 2012 is no exception.

AMS Instrumentation & Calibration Pty Ltd (AMS) has been in existence for close to 40 years providing calibration equipment and industrial instrumentation to wide range of industries. With more than 200 years of instrumentation experience among its staff and now with branches in every major city, AMS is confident it can offer its customers the best solution to fill their needs. “Last year, AMS evolved and “split” into the three areas which are considered growth sectors for our organisation,” says Dirk Kuiper, General Manager, AMS Instrumentation & Calibration. Calibration hardware and software is one area and the others are Flow, Pressure and Level plus the newly created area of Analytical Instrumentation following AMS’s appointment as distributor of several highly-regarded analytical suppliers. “We feel we are able to fully assist our end-users to optimise their processes and performance,” says Kuiper. The majority of the products represented by AMS are widely used in the oil & gas industry, hence AMS’s support for this category. AMS sees the Zenith Awards as a major feature in our industry to reward the innovation and achievements of products and people and as such are very proud to be associated with the awards. AMS has been supporting the Zenith Awards since its inception nine years ago.

ifm efector 1300 365 088 www.ifm.com/au

AMS Instrumentation & Calibration 1800 804 516 www.ams-ic.com.au

Lifetime Achievement Award

Water & Wastewater

For decades LogiCamms’ people have supported a diverse portfolio of customers both in Australia and internationally with engineering, project delivery and asset management solutions. The company’s journey has seen it transform from individually successful engineering businesses into a leading multidiscipline, ASX-listed organisation with a common Vision – To be a market leader delivering outstanding customer solutions. With this Vision and LogiCamms’ foundation capabilities in Automation, Control Systems and Electrical engineering, the company is proud to sponsor the highly revered category in this year’s PACE Zenith Awards, the Lifetime Achievement Award. “This Award recognises a longserving, high calibre professional who has delivered a meaningful contribution to the industry,” said LogiCamms’ Managing Director, Steve Banning. “It is also recognition of the qualities in people that our organisation celebrates including leadership, innovation, and dedication to their craft. We welcome the opportunity to recognise excellence in the field at the highest level,” he said. LogiCamms has expanded during a period of strategic growth to over 450 personnel, and operates within key industries that are shaping our nation’s future including mining & minerals, oil & gas, power & water, sugar & ethanol, as well as phosphates. One of LogiCamms’ benchmark achievements is delivering the Process Control System for the $3.5 billion Victorian Desalination Plant, which will be one of the largest applications of the selected technology in the southern hemisphere.

Endress+Hauser is proud to be part of water treatment in Australia and in particular desalination. “We have been a major supplier of instrumentation in the large desalination plants built in Perth, the Gold coast, Sydney and, more recently, Melbourne,” says Chris Gailer, Managing Director, Endress+Hauser Australia. When fully operational, the Melbourne plant will be the largest plant in Australia, supplying 150 billion litres of water a year to Melbourne and surrounding areas. We acted as consultants for the selection of technology and detailed engineering of measurements; for just over a year an Endress+Hauser engineer was embedded as part of the project team. We were also proud to have supplied all the instrumentation for the Grundfos dosing skids, and the Air Liquide CO2 plant. There is some irony in Melbourne desalination plant, as high levels of rainfall have hindered its completion. Whilst the desalination plant might be under utilised in the short term, we see that providing irrigation to the city’s outlying areas, with continuous and substantial volumes of water, will create many opportunities for those regions. We also see that while Australia is unlikely to require any more big desalination plants, there are many remote regions in Australia that will benefit from smaller desalination plants. These will need to be more efficient and more customisable for specific regional requirements.

LogiCamms Ltd 08 6331 8888 www.logicamms.com.au

Endress+Hauser 02 8877 7000 www.au.endress.com

16 www.pacetoday.com.au MARCH 2012

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PACE ZENITH AWARDS 2012 SPONSORS

The Zenith Awards recognise technical excellence and leadership in engineering across ten categories. This year sees the addition of the Machine Builder category. PACE magazine thanks the sponsors for supporting this premier event.

Mining, Minerals & Exploration Power and Energy Management

Young Achiever Award

“In recognition of those organisations leading our industry with sustainable and innovative solutions, Schneider Electric is proud to sponsor the ‘Mining, Minerals & Exploration’ and ‘Power and Energy Management’ categories of the 2012 PACE Zenith awards,” says Scott Wooldridge, Vice President, Industry Business, Schneider Electric. With energy demand set to double by 2050 and energy prices continuing to increase, energy management is becoming the number one issue for businesses and consumers. With significant savings possible, industry has a compelling, commercial incentive to conserve energy through efficient installation, device optimisation, automation, monitoring and rigorous maintenance. As part of our ongoing commitment to make energy safe, reliable, efficient, productive and green, a key priority for us in 2012 is to provide customers with intelligent energy management systems. In doing so, we can help businesses achieve significant energy savings through the use of passive and active energy efficiency strategies. Utilising our proven EcoStruxure approach, Schneider Electric delivers simplified systems that save money and most importantly, reduce waste by enabling a guaranteed compatibility between the management of power, white space, processes and machines, building control and security. EcoStruxure delivers real-time visibility of business performance and brings users together through compatible product designs and open-platform software. It provides end-users with the critical tools needed to reduce their design time, CapEx and OpEx.

SICK Pty Ltd celebrates its 30 year anniversary this year of direct support into the Australian and New Zealand industrial and process market places. This year sees new corporate headquarters for SICK in Australia at Heidelberg West, three times the size of the previous building. The new facilities with a massive new warehouse enable increased stock levels to further support industry requirements. The application and innovation centre, combined with excellent training facilities for hands on training and technical seminars continue the high level support. Our new lifetime services facility combined with an expanded customer service centre will provide the industry benchmark for service. “Our new headquarters will further facilitate the ongoing high level of commitment to our customers for developing and proving automation solutions well into the future,” says David Duncan, Managing Director, SICK. As an independent company SICK continues to drive innovative sensor intelligence across all industry sectors of Factory, Logistics and Process Automation. The leadership that SICK has shown in providing leading edge technologies is one of the reasons that we proudly support the PACE Zenith Awards and in particular the Young Achiever Award. This award aligns with the philosophy of SICK to maintain independence, create innovation and ensure leadership of next generation sensing technologies which we encourage our young achievers to pursue.

Schneider Electric 1300 369 233 www.schneider-electric.com.au

SICK Pty Ltd 1800 334 802 www.sick.com.au

Machine Builder

Food & Beverage

In a climate of pessimism for Australian manufacturing, one of the good news stories is the thriving position of local machine builders. “Once the domain of the Germans and the Italians, and more recently China, Australians are gaining an international reputation for building machines that not only address contemporary concerns of safety and business system integration, but provide the design and operational flexibility not always evident out of European manufacturers,” says Eugene Mayevsky, Sales Manager, Daanet. The innovation displayed in this new dawn of Australian manufacturing is much like the approach taken by Austrian company B&R Automation in their quest to differentiate themselves from larger and better known automation companies in Europe. By sponsoring the Machine Builder category of the PACE Zenith Awards, B&R Automation hopes to identify with all automation users looking for an alternative approach to both traditional and new problems. With products like HMIs with embedded control and I/O, Automation PCs with a built-in UPS, and application development software that fully integrates with 3rd party design tools like MathWorks MatLab, B&R Automation has something special to offer: Innovation.

“We are proud of our continuing association with the PACE Zenith awards and congratulate the winners in advance,” says Siemens Industry Vice President, David Keenan. Since the company’s contribution last year, Siemens has launched a comprehensive research program titled Picture the Future 2030: Productivity. The research explored many of the challenges facing Australia, such as declining productivity. We recognise that the manufacturing industry in this country is doing it tough at present but we believe Australia can and should be one of the world’s industrial powerhouses. In Germany where the Euro is high and labour rates are similar to those here, manufacturing remains very strong. The right mix of innovation, technology and collaboration between government and within the sector has ensured the country’s global competitiveness. But this cohesive approach appears to be lacking in Australia. Take our freight and logistics — it currently costs more to ship from Melbourne to Sydney than from Melbourne to Asia. We need forwardthinking solutions, such as intermodal hubs where our ports, trains and trucks connect seamlessly. Technology platforms, like Siemens’ Simatic TIA Portal can increase engineering efficiency by enabling the user to design automation processes optimally, from a single computer screen, along the entire value supply chain. Technology can assist in making Australian companies more cost competitive. Through this sponsorship Siemens can recognise the role the engineering community plays in creating a viable and sustainable future for Australian manufacturing.

B&R Automation www.daanet.com.au www.br-automation.com

Siemens Ltd 137 222 (Australia)/+64 9 580 5500 (New Zealand) www.siemens.com.au MARCH 2012 www.pacetoday.com.au 17

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IN FOCUS

Why ‘Industrial Ethernet’ is more tha n A structured and total lifecycle approach to Industrial Ethernet will improve the performance, reliability, scalab ilit

INTERCONNECTED: A screen capture of a network topology.

HE increasing use of digital equipment in industrial environments coupled with increased integration and data bandwidth requirements has led to growing adoption of Ethernet (IEEE 802.3) for communication in place of older serial-based communication systems. However, simply selecting ruggedised versions of Ethernet equipment originally designed for conventional IT environments will not create a true Industrial Ethernet network. Ruggedness is important, but it is only one part of a much larger picture. An excessive focus on particular physical characteristics such as temperature and vibration specifications leads to other crit-

18 www.pacetoday.com.au MARCH 2012

ical factors being overlooked, and hence inappropriate purchasing decisions. System-wide considerations have a bigger impact than the physical characteristics of an individual component. Fitting a race-tuned engine to an otherwise standard car will improve its performance, but it won’t match a fully prepared racing car with the same engine.

Remote monitoring Power and torque are only part of the story — suspension, brakes, tyres and so on all contribute to how quickly the car can get round the track and whether it will last the distance. A racing car also needs features for quick repairs or replacement (for

example, the single nut securing a wheel to the hub instead of the four or five used on most road cars) and remote monitoring and diagnostics to ensure success.

Physical network Similarly, Industrial Ethernet is about the entire network. The physical network consists of cables, connectors and active components such as switches and routers, all of which affect end-toend signal transmission. A deep understanding of how they work together allows the design of a network that will operate effectively under the challenges of an industrial environment. The physical design must also be

complemented by an equally well thought out logical design including addressing and segregation. Other critical factors that must be considered include ease of configuration and diagnostics, network and cyber security, network management tools, redundancy protocols, automation integration, and remote access.

Initial design It is important to consider the total lifecycle of a project from initial design through engineering, commissioning, operation, maintenance, and any later upgrades or expansion. Physical specifications are important to the initial design process, but other factors will arise later in the total life-

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ha n just ‘Industrial’ + ‘Ethernet’

, scalab ility and longevity of your network, writes Justin Nga. cycle, especially during operation, maintenance, expansions and upgrades. Proven reliability and maintainability are also more important than bandwidth alone for automation and control systems, whether you are coming from the perspective of occupational health and safety or the need to avoid production downtime.

The physical design must be complemented by an equally well thought out logical design including addressing and segregation.

to shutdown part of an IT network for a period of time (for example to install additional network equipment), that luxury is rarely open to the person in charge of a factory or process control network where 24x7 operation is the norm.

Important statistic

This also impacts on maintenance: while mean time to failure is an imporMany industrial environments recognise tant statistic, mean time to repair is made for products that come with webthat the personnel who will operate crucial, especially as Murphy’s Law based, graphical, easy to use software and maintain the network may not be dictates that any failure however unlikely configuration and diagnostic interfaces, IT specialists, and are then tempted will occur at the most inconvenient time and with options that can be set via DIP to install basic unmanaged network and location. switches, which are familiar to the electriswitches in the name of simplicity. Where IT equipment is usually cians likely to be charged with installation With advancements in Industrial replaced and modifications. A D _ P A C E I N V MA R _ 1 2 . p d f Pa ge 1 1 5 / 0 2 / 1 2 , 9 : 0 on 2 :a three 5 3 toAfour M year A Ecycle, DT Ethernet today, a case can readily be the components of an industrial network Although it may be acceptable

Unmanaged switches

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can easily be in operation for 10 years or more. If you need to replace a faulty device after several years, will the backup of its configuration be easily retrievable? Will the replacement have the same firmware to ensure sitewide compatibility? Can the old firmware and configuration be saved and restored from removable media without involving a computer? How long will expansion modules (for example, additional ports) be available for the base unit you purchase today? How long will the supplier provide a repair or replacement service in the > event of hardware failure?

5HPRWH HQJLQHHULQJ FDSDELOLWLHV ZLWK , $ 6HULHVp ,QWHOOLJHQW 0DUVKDOOLQJ NHHS \RXU SURMHFW RQ WLPH DQG RQ EXGJHW ✔ (OLPLQDWH PDUVKDOOLQJ ✔ ,QFUHDVH , 2 GHQVLW\ ✔ 5HGXFH ŵHOG ODERU FRVWV ✔ 'HFUHDVH LQYHQWRU\ VSDUHV ✔ &DVWHU LPSOHPHQWDWLRQ ✔ )DVWHU VWDUW XS WLPH ,QWURGXFLQJ D XQLYHUVDO , 2 PRGXOH WKDW HOLPLQDWHV 0DUVKDOOLQJ DQG LV VRIWZDUH FRQŵJXUDEOH ZZZ LRP LQYHQV\V FRP ,QWHO0DUVKDOOLQJ

MARCH 2012 www.pacetoday.com.au 19

PACE.MAR12.PG020.pdf

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IN FOCUS

Management Level

Office Network EAGLE

EAGLE

Operator Panel

Field Device Tool/ FDT

Security (Engineering, SCADA, Asset Management)

Backbone

Industrial HiVision

Network Management MACH4000

MACH4000

Server MACH100 MS30

Redun dant HIPER -Ring

PLC

BAT54-Rail

Wireless LAN

Control RS30

RS30

Control Level

MS30

Mobile Operator Panel

HMI Camera

Security

EAGLE

Mobile Client BAT54-F

EAGLE

RS20

M12 Data Connectors

RS20

Mobile Client

BAT54-F

Redundant HIPER-Ring

RS20

Profibus DP

OZD Profi

PLC

OZD Profi IP67Gateway

SPIDER

PLC

Hazardous Location

Gateway

PLC

MICE ATEX

e2c67

Gateway ATEX PLC

LDB LioN

LioN LDB

LioN-Link LioN

Gateway

LioNLink

M8/M12 Cord Sets

Fiber Optic Connection

Field Level

OCTOPUS

RS20

LDB

GDM series Rectangular Connectors

HART

OZD Profi ATEX

Profibus PA

OZD Profi ATEX Fiber Optic Connection

e2c67

Round and Rectangular Connectors

Profibus DP

Actuators and Sensors

DESIGN: A detailed top down plant overview of a complete industrial ethernet network.

Industrial environments Some vendors have a total lifecycle perspective of the Industrial Ethernet network solution intended for industrial environments, while others plainly stop at physical ruggedisation. A sensible approach to Industrial Ethernet design and implementation is to start by understanding the application and site-specific issues. Begin by considering the physical environment and some basic architectural issues. Will the network hardware be installed in 19-inch racks, DIN rails or a combination? What are the available power supplies at that location? What is the temperature range? Are there any airborne contaminants (such as the hydrogen sulphide present in water treatment plants) that may be conductive or corrosive? How much bandwidth will be required? Where and how will the physical cabling be run? Is 20 www.pacetoday.com.au MARCH 2012

Proven reliability and maintainability are more important than bandwidth alone for automation and control systems. fibre or copper cabling more appropriate due to distances or electromagnetic interference? Then consider an appropriate network topology (e.g ring, star or a combination). Complement the physical topology with the appropriate logical network design for addressing and segregation. Which automation system is in use or will be used? Can the Industrial Ethernet network be seamlessly integrated with the automation system?

Who will configure and maintain the network itself - IT personnel, automation engineers or electricians? What are the network security measures to be implemented? What network management tools are proposed? What existing network infrastructure will be retained or reused? Will a partial network migration be required, and how will the older and newer networks coexist? Even something seemingly as basic as cabling deserves careful consideration. Proper physical cabling design and installation has largely been ignored as most industrial networks typically carry smaller packets of data and operate well below capacity. However, once a network begins to grow and the utilisation increases, poor physical cabling will eventually result in performance issues and lack of scalability. Industrial environments are often

subject to vibration, dust, oil, moisture, UV exposure, and vermin, which are not usually significant issues in the typical office or data centre.

Suitable materials A correctly specified cabling solution should include jacket materials suitable for the environment, and factory-tested patch leads with moulded boots and suitable connectors. Only a minority of people currently consider the comprehensive design and implementation approach described above, but a structured and total lifecycle approach to Industrial Ethernet will improve the performance, reliability, scalability and longevity of your network. [Justin Nga is Business Development Manager, Belden Industrial Solutions.] Belden 1800 500 775 www.beldensolutions.com

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Every single flowmeter I calibrate interrupts my process. There must be a way to verify meters without putting my plant and people at risk.

NDJ 86C 9D I=6I

Verify flowmeter performance in place with Micro Motion Smart Meter Verification. Determining measurement integrity and performance of every meter in line means never stopping your process flow. Emersonâ&#x20AC;&#x2122;s Smart Meter Verification for Micro Motion Coriolis meters is the only automatic diagnostic tool that eliminates the need to break process seals, allowing you to avoid potential safety issues and costly process flow interruptions. So to keep your workers safe and your operation running, go to EmersonProcess.com/Verification For Further information, please contact Sambit Das, National Business Manager Phone : + 61 (03) 9721 0200 E-mail : Sambit.Das@emerson.com The Emerson logo is a trademark and a service mark of Emerson Electric Co. ÂŠ 2011 Emerson Electric Co.

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BEHIND THE SCENES

Networks installed at Curragh Mine The project to upgrade the network at Curragh’s Coal Handling Preparation Plant had to overcome some unforeseen hurdles that called for innovative solutions by the engineering team.

ACE Engineers Group (not associated with PACE magazine in any way) and Belden Australia have worked together to install two connecting Gigabit Ethernet networks at Queensland’s Curragh Mine, operated by one of Australia’s largest independent coal producers. Like all plans on paper it seemed straightforward, but complications with existing infrastructure and issues that surfaced after hours on a Friday evening looked set to cause undesirable delays to a scheduled plant shutdown. The mine currently produces 6.5 million tonnes of export coal and 2.5 million tonnes of domestic coal per year comprising hard coking coal, PCI coal and steam coal. Open cut reserves at Curragh allow production levels to be maintained to at least 2025.

Network connections Following PACE Engineers Group’s (PEG) successful network upgrade for Curragh’s Coal Handling Preparation Plant 1 (CHPP1) earlier in 2011, they were again engaged to assist in connecting a new CHPP network (CHPP2) to the CHPP1 network. PEG were engaged on these projects as part of its role in the CHPP owner’s team support. The company is Australian owned and operated, providing professional services in the electrical and IT disciplines with experience in the mining, minerals processing, energy, industrial and commercial industries. Assistance was also provided in the connection of CHPP2 to the CHPP1 network which includes all areas of the CHPP including train loading, raw coal and control rooms. PEG designed the interconnection between the new and older wash plants by utilising Hirschmann RS40 components and achieved a seamless connection and commissioning without incurring any downtime or interruption to the running of the plant. The connection between the plants has been 22 www.pacetoday.com.au MARCH 2012

A re-engineered solution was required to ensure long term functionality and high production availability that could be maintained for the life of the mine.

operating without any issues. Prior to the commencement of either project, Curragh engaged PEG to undertake a feasibility study on the existing network to identify shortcomings as it was operating in a heavily congested state. This congestion was resulting in a loss of data, which in turn further choked the existing capability to a level where functionality for production was

being compromised. These system issues had the potential to impact production capability. Therefore a re-engineered solution was required to ensure long term functionality and high production availability that could be maintained for the life of the mine. The CHPP1 network upgrade and change management system was designed by PEG based on Belden’s Hirschmann RS40 range of compact configurable managed industrial 9 port full Gigabit Ethernet switches.

Poor condition Details of the design were provided to Curragh to allow them to advise their stakeholders of the systems and infrastructure that were to be installed in the existing plant. This allowed Curragh to make allowances with full knowledge of how the interconnections between the plants would best operate.

An issue arose during the implementation of the equipment due to the poor condition of the existing optical fibre cable infrastructure. This problem wasn’t identified during the investigation phase because the existing network was not able to be interrupted for backbone testing. This issue caused the rollout to be put on hold mid installation with the likely scenario to cancel and implement a rollback plan. While a decision was made to prepare for rollback, PEG meanwhile called Belden’s support service on a Friday evening. After the issues were detailed, the Belden support engineer recommended an alternative course of action. Following this alternate methodology, PEG was able to continue its implementation of the network as designed and within the scheduled plant shutdown period. Chris Ward, PEG’s lead control >

AD_PACESCHMAR_12.pdf

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We’re as passionate about our equipment as you are about your process Experts in bulk material handling for more than 125 years.

weighing

feeding

screening

Schenck Process Australia Pty Ltd Ground Floor 65 Epping Road North Ryde NSW 2113, Australia T 1300 551 645 Australia wide T + 61 2 9886 6800 outside of Australia sales@schenckprocess.com.au www.schenckprocess.com.au

automation

We understand that keeping your process running efﬁciently with minimum down time is your number one priority. That’s why our staff work relentlessly to provide you with the most reliable equipment money can buy. At every step, be it application engineering, design, project management, manufacturing, despatch or commissioning, we are there by your side to ensure that your process runs smoothly and proﬁtably.

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BEHIND THE SCENES

SUPERIOR: Chris Ward was pleased with the service and support he received.

An issue arose during the implementation of the equipment due to the poor condition of the existing optical fibre cable infrastructure. systems designer, said, “Whilst this support request was made after hours on a Friday afternoon we held little prospect of receiving such valuable support expertise. Belden’s technology and support services locally have proven to be superior to that offered by many suppliers to the industry”. During the last quarter of 2011, PEG commenced installation and commissioning of the second network, including dual power supplies and optimising network device connections. PEG engineers were able to bring the data connections between the network it upgraded earlier in the year and the new coal wash plant online without the need for any downtime for either operation.

Fanless design During the design phase for the existing wash plant, allowances were made for the connections between the two wash plants utilising Hirschmann’s Gigabit Ethernet managed switches, with Layer 2 Enhanced software for DIN rail store-and-forward-switching incorporating a fanless design. When the new wash plant was coming online PEG was able to connect the new wash plant to the old wash plant via redundant links without interruption. “This demonstrates the flexibility of the 24 www.pacetoday.com.au MARCH 2012

Hirschmann redundant networks using HYPER Ring technology. With no additional configuration required to the old plant, the new plant could be connected months later when construction was completed,” Ward said. “The high level of support and product knowledge from Belden was second to none. This greatly assisted our engineers during some very testing times encountered during these projects. The outcome was a very successful installation and commissioning phase without interruption to the client’s production. “The flexibility and reliability of the Hirschmann HYPER Ring and ring coupling configurations allowed us to provide our client with a high quality, redundant, high speed solution that met their present and future needs.” Kjell Schwab, a PEG control systems engineer who was involved in the Curragh projects, recently attended the inaugural three-day Belden Mission Critical Network Design Seminar. He said: “Sessions and workshops provided knowledge-building training that further developed my understanding of not only Hirschmann products but how they fit into the network as infrastructure providers. The content, delivered particularly through handson training with Belden and Hirschmann experts, allowed for experimentation time with a simulated large network. This has allowed me to increase my level of understanding of all network installations.” PACE Engineers Group 07 3835 0000 www.paceengineers.com Belden 1800 500 775 www.beldensolutions.com

AD_PACEWEIMAR_12.pdf

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AEDT

PACE.MAR12.PG026.pdf

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BEHIND THE SCENES

The challenge of developing integrated s An Orica joint venture nitric acid plant in the East Kalimantan province of Borneo Island implements an integ ra logistics and covering primary processes as well as downstream output logistics, writes Hartley Henderson.

T BONTAG, in the Indonesian East Kalimantan province of Borneo Island, PT Kaltim Nitrate Indonesia (KNI) has completed the construction of a Nitric Acid Plant, plus an Ammonium Nitrate Plant to produce prill (pellets) that are used as explosives for the burgeoning Indonesian resources sector. KNI is an Orica joint venture company. Design life of the facility is 20 years, and the joint capacity of the production plants is 300,000 metric tonnes per annum. Due to the nature of the products manufactured at this site, precision and safety in processing the chemicals are high priorities. Exacting requirements, including human, environmental and equipment protection, are vital at all stages of the process. Siemens Australia provided a control and safety solution that comprised automation control, visualisation, and reporting on all aspects of the plant, particularly in relation to production of the ammonium nitrate prill. The company managed the project locally, working closely with the Orica team based in Melbourne. Central to the control systems for the complex is the Siemens SIMATIC PCS 7 high performance process control system and its integrated process safety solution.

Integrated automation The company’s lead project engineer, Daniel Smalley, says the SIMATIC PCS 7 is a significant component of Totally Integrated Automation (TIA), and forms a unique basis offered by Siemens for uniform and customised automation in all sectors of production, process and hybrid industries. “Through our PCS 7 industrial control system we were able to interface with the plant’s MAN turbo machinery, which is also controlled and managed using a MAN custom PCS 7 solution,” he explained. “This system offers uniform automation technology on one single platform for all applications of process automation, starting with input logistics and covering production or primary processes 26 www.pacetoday.com.au MARCH 2012

PROCESSING: Exacting requirements are vital at all stages of the process at Orica’s KNI plant.

The integrated safety system maximises process plant safety and is scalable from simple to complex processes enabling hazards to be minimised without compromising production. as well as downstream output logistics. “The integrated Siemens Process Safety F-System maximises process plant safety and is scalable from simple to complex processes up to SIL3, enabling human, system and environmental hazards to be minimised without compromising production. “The safety system visualisation uses Siemens propriety cause and effect visualisation package Safety Matrix which gives quick and logical graphical representation of the trip status. Safety system trips may be caused by factors such as high or low temperature, low pressure, or by human intervention via an emer-

gency stop button. “The viewer of the SIMATIC Safety Matrix, which can be used on the SIMATIC PCS 7 operator station, permits simple operation and monitoring of the safety operation during runtime.” SIMATIC Process Device Manager is used to configure field devices by different manufacturers and monitor selected process values, alarms, and status signals of devices on line using a single user interface. Marshalled Terminations Assemblies enable field devices, sensors and actuators to be simply connected to the I/O modules of Siemens ET 200M remote I/O stations.

Time synchronisation Smalley says the project also features a Siclock plant-wide GPS Ethernet clock which is a programmable, modular and optimally matched system for time synchronisation of the plants. “The use of a common GPS Ethernet clock allows plant-wide time synchronisation of all hardware and software, giving a true sequence of event alarm system that allows quick identification of the first out alarms, maximising performance,” he said.

“Siemens Scalance X200 Managed Industrial Ethernet Switches are also installed to provide a reliable optimal solution for the Ethernet communications network. These switches have a host of functions, such as SNMP diagnostics, and they increase plant availability thanks to their integration into PCS 7 for simple commissioning and engineering. “In addition, Siemens Scalance S Security Modules are provided to ensure Firewall and VPN security and meet the special requirements of an industrial environment. SIMOCODE has been connected to the automation system via PROFIBUS DP to provide a flexible and modular control system for low voltage motors. It covers all functional requirements between the motor starter and the automation system, including the fail-safe disconnection of motors. “Further protection functions are provided via Siemens Sentron 3WL Air Circuit Breakers and Siemens 7SJ80 Siprotec Overcurrent Protection Relay. Sentron meets the increased requirements placed upon air circuit breakers, particularly in relation to electronic control systems, while Siprotec enables 20 additional protection functions to be created by the user including a rate of change frequency function.” While this entire project was managed from Australia, software and hardware were commissioned out of Indonesia to overcome any possible language and geographical issues. Siemens Singapore Chemical Centre of Competence undertook the complex calculations such as steam tables, and experts from Siemens Germany accompanied Orica’s engineers in Germany to plan the MAN Turbo PCS 7 interface to ensure the smooth integration of hardware and software on site.

Challenges Smalley advises that a key challenge encountered during the project was managing information and control through multiple stakeholders in different countries internally (Siemens in Singapore, Siemens in Germany,

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d solutions for a chemical plant eg rated technology solution on a single platform for all process automation applications starting with input avoid any miscommunication.” Orica company electrical engineer, Abdul T Ali, emphasises that integrated control and safety systems, Profibus communication, and HART communication are critical to the success of the Ammonium Nitrate manufacturing facility for a number of reasons. “The integrated Distributed Control System (DCS) and Emergency Shutdown System provides a high level of diagnostic information from shutdown system to operator screen, such as a dynamics cause/effect matrix, trip and interlock status, and synchronised alarm time stamping from field devices,” he said. “Other critical elements of the project include electrical motor and vari-

able speed drive control and diagnostic capability through the Profibus network, and asset management through DCS/ SIS HART pass through I/Os for field transmitters and valve positioners. “Electrical HV and LV distribution, DC and AC UPS, and emergency generator monitoring through the Profibus network are also key factors for operational effectiveness.” Orica Australia 1300 555 175 www.orica.com Siemens Australia 137 222 www.siemens.com.au

STREAMLINED: The plant employs a uniform automation technology on a single platform for all applications of process automation.

Siemens Australia, Siemens Indonesia), and externally (MAN Germany, Uhde Shedden Australia, Orica Australia, PT Kaltim Nitrate Indonesia and Rekayasa Indonesia). “To manage this situation technically we used the flexibility of PCS 7 to import and export project data in a comma separated variable (CSV) format to allow a free flow of data no matter who the stakeholder was. PCS 7 is also based on open standards, which allows

us to integrate any certified third party Profibus devices,” he explained. “To manage the situation for project execution we relied on the internal common PM@Siemens (Project Management at Siemens) project management methodology which is based on the Project Management Body of Knowledge (PMBOK). Siemens uses PM@Siemens methodology to deliver projects worldwide, giving a consistent delivery model and using consistent language to MARCH 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.

Clamp-on ultrasonic flowmeter

Digital manometer KELLERâ&#x20AC;&#x2122;s high-accuracy LEO 2 digital manometer is designed to handle demanding monitoring tasks in the plant and machinery manufacturing sector. In the compensated temperature range from 0...50 Â°C, this microprocessor-controlled instrument records two measured values per second with typical overall accuracy of 0.1 % FS. The dual digital display updates twice every second, showing the measured value and the minimum or maximum value attained. Two ergonomically positioned keys give the operator reliable access to the microprocessor-based functionality of the LEO type manometer. As well as a choice of five different units of measurement, the two-key operating system provides access to the entire range of functions: the stored max/ min can be erased and reset to zero, or the device can be switched to continuous mode. In continuous operating mode, the battery has capacity for up to 1,400 hours. The LEO 2 has a standard automatic switch-off time of about 15 minutes after the last key was pressed, this function extends the battery life where continuous operation is not required. LEO 2 also offers an unusual operating mode that is highly relevant under practical conditions: It has a Zero Tare feature which allows the user to set the zero at any pressure, so the manometer will then always show deviations from the Zero Tare. KELLER info@keller-druck.com www.keller-druck.com 28 www.pacetoday.com.au MARCH 2012

The KATflow clamp-on ultrasonic flow meters work on the transit-time method based on the principle that sound waves travelling with the flow will move faster than those travelling against it. The ultrasonic transducers of the flow meter are mounted on the external surface of the pipe and are used to generate and receive pulses. The flowing liquid within causes time differences in the ultrasonic signals, which are evaluated by the flow meter to produce an accurate flow measurement. The advanced electronics of the flow meter compensate for and adapt to changes in the flow profile and medium

temperature to deliver reliable measurements. The KATflow 200 hand-held ultrasonic flow meter may be used for noninvasive and non-intrusive flow measurement of liquids and liquefied gases in fully filled pipes. AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au

Pressure transmitter for demanding applications The TX200 is suitable for offshore oil and gas instrument panels, wellhead monitoring, blowout preventors, measuring tubing and casing pressure, pipeline monitoring, and other offshore/onshore oil and gas applications. It is UL listed and ATEX compliant for Class I, Div. 1 areas. Available pressure ranges are 0 to 100 psi, up to 0 to 25,000 psi. Range models may be ordered as either fixed or adjustable, with the adjustable models capable of being calibrated in place and featuring non-interactive zero and span, allowing for quick adjustment of the TX200. Welded, hermetically sealed and constructed of 316 stainless steel, this transmitter is designed to withstand the harshest environments while conserving space. Pryde Measurement 1800 688 211 www.pryde.com.au

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

Compact occupancy and light data logger Onset has released the HOBO UX90 Occupancy & Light Logger, a matchbox-sized, LCD-display data logger that tracks building occupancy and light usage to pinpoint areas in a building that could benefit from occupancy sensors and other energy savings initiatives. The data loggers can collect time-stamped data documenting each time room occupancy or lighting status changes. The compact data loggers may be mounted to lighting fixtures, ceilings and walls, and can be set up and installed in less than a minute. Once data has been recorded with the HOBO UX90, it can be viewed in graph form using accompanying HOBOware software, and printed out. The data can be exported to Microsoft Excel for more detailed analysis. new toolbox suite includes data loggers for measuring motor on/off status, electronic pulses, state changes and light use patterns. OneTemp www.onetemp.com.au 1300 768 887

Humidity transmitters with Profibus Interface Testo’s series 6651 and 6681 humidity measurement transmitters are designed for monitoring critical climate in process engineering and in compressed air technology. The optional Profibus DP interface in the 6681 allows direct connection to the Profibus factory automation so that measurement values as well as reports are forwarded. Apart from this, parameterisation can also take place ‘from above’, for example setting the alarm limit for the relays. The transmitters also incorporate the intelligence required for self-monitoring, so that early warnings,

OpenBAT tailor-made WLAN access points Belden’s OpenBAT range from Hirschmann is the first modular system to enable industry-standard WLAN access points and clients to be configured via the internet. This range, comprising the BAT-R (IP20) and BAT-F (IP67) series, supports IEEE 802.11n, which facilitates data speeds of up to 450Mbps in both the 5GHz and the 2.4GHz bands. Both series have a HiLCOS operating system with management, security and quality of service functions plus layer 3 IP routing. The number of wireless modules and Ethernet LAN ports can be configured individually, as can the power delivery concept. Suited to the power supply industry, the gas and oil sectors and rail transportation, they can be used to set up infrastructure and meshed networks plus WDS or point-to-point connections. Belden 1800 500 775 australia.sales@beldenapac.com

such as sensor drift are emitted. Also offered are calibrated and exchangeable probes as well as probes designed for special applications such as high humidity and corrosive media. The measurement transmitters continue to use existing technology such as the external interface for communication - the parameterisation and adjustment software P2A from testo. The optional Profibus DP interface may be integrated at a later date. testo 03 8761 6108 www.testo.com.au

Smarter particle sizing With an extended dynamic range that spans 0.01 to 3,500 microns, the Mastersizer 3000 laser diffraction particle size analyser delivers precise wet and dry measurements across the milli-, micro- and nano-meter size ranges. The optical core packs high performance into a compact system that boasts well-engineered sample dispersion accessories. The Aero S dry powder unit disperses a range of dry materials, even friable and fragile powders without inflicting particle damage. Intuitive software drives Mastersizer 3000 measurements, bringing operator-independent analysis and offering data generation and presentations tailored to customer needs. ATA Scientific 02 9541 3500 www.atascientific.com.au MARCH 2012 www.pacetoday.com.au 29

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COMMUNITY

TOP TWEETS

WHAT’S ON

Rockwell Automation on the Move 6-7 March 2012, Melbourne au.rockwellautomation.com IICA/ISA: Overview of Measurement & Control Fundamentals 7 March 2012, Sydney www.iica.org.au HAZOP Study for Team Leaders and Team Members 13-15 March 2012, Brisbane www.icheme.org/hazopbris TÜV Functional Safety Program 27-30 March 2012, Perth www.hima.com.au/tuv IICA/ISA: Instrumentation Diagrams & Symbols 28 March 2012, Brisbane www.iica.org.au IICA/ISA: Safety Instrumented Systems 18 April 2012, Melbourne www.iica.org.au

For daily updates visit www.pacetoday.com.au

Here’s what you may have missed this February if you weren’t following @pacetoday on Twitter: ❏ WA’s Cape Riche Desalination Plant given conditional approval http://dlvr.it/1CB26k

❏ Industrial Scientific recalls GasBadge Plus, cites detection fault http://dlvr.it/18rfmn

❏ Cardno BEC secures major Brownfield project with Rio Tinto http://dlvr.it/1BnnZY

❏ Jeff Connolly appointed CEO of Siemens in Australia http://dlvr.it/18rTnZ

❏ Chevron JV to offer contracts worth $12.8 billion to local business http://dlvr.it/1BlVv4

❏ Faulty valves discovered in Victoria’s Wonthaggi desalination plant http://dlvr.it/18cTDy

❏ Suppliers demonstrate support for WirelessHART http://dlvr.it/1BCQDC

❏ Patent research identifies latest innovations in the integration of desalination with renewable energy http://dlvr.it/18c1Xt

❏ Advanced diagnostics embedded in a pressure transmitter can detect integrity issues http://dlvr.it/19lrgg ❏ Siemens to acquire network supplier RuggedCom http://dlvr.it/19lcTS

❏ Siemens broadens wastewater and water treatment portfolio with acquisition http://dlvr.it/18CbPN ❏ Emerson introduces configuration and diagnostics tool for Coriolis flow and density meters http://dlvr.it/16qvJG

❏ Apprenticeships now allow accelerated training http://dlvr.it/19Kf4d

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

VIEWPOINT

The IC&A’s contribution Let’s take a realistic look at the industry sectors that employ us, writes Brett Simpson. DOOM and gloom. The news on virtually all means of communication seems to be focussed on the GFC and its aftermath, the potential disintegration of the Euro zone and on the imminent (depending on your sources) demise of Capitalism, as we know it. So what are we to make of it? ‘Normal’ everyday people like you and I are not exactly in any realistic positions to alter or change the course of any economic catastrophe about to hit us, are we? So it seems to me that now is as good a time as any to have a realistic and unemotional look at the industry sectors that employ us or within which we operate as players. I am of course specifically referring to those instrumentation, control systems and automation (IC&A) sectors that 30 www.pacetoday.com.au MARCH 2012

make up quite a large segment of readers of this magazine. We collectively participate in almost all key areas of activity, from mining, oil, gas, telecommunications, electronics, aerospace, automotive, pharmaceutical, chemical, agribusiness and the list goes on - to the TAFEs and Universities which teach and prepare students for employment in those areas. By my reckoning, pretty well all of these underpin our economy and will not disappear overnight. Most will continue to thrive in the 21st century. But what is also certain is that each will experience change - dramatic, gradual or possibly evolutionary - depending on the sector. How each sector prepares itself, in terms of its employees - current and future: its long term policies and planning and its ability to marshal leading

edge technologies and innovative solutions to specific problems - to mention just a few key issues - will be deciding factors that will determine their future viabilities. I therefore want to conclude this article by posing four questions that I believe require serious consideration by all sectors where IC&A engagement occurs in Australia. ❏ “Are Australian TAFEs and Universities equipped to be able to provide current and future students with world’s best education in areas of IC&A to ensure they can succeed in a globalised and increasingly competitive environment?” ❏ “In the increasing globalisation of companies and employment opportunities offshore, are there sufficient

opportunities in Australia for IC&A employees, graduates and/or apprentices to access the availability of globally recognised qualifications?” ❏ “Are there sufficient incentives and/ or interest by companies in Australia to invest in R&D in areas of cutting edge technologies that will ensure their long term viability and competitiveness, especially from emerging countries that seem to really appreciate the value of R&D?” ❏ “Are Australian politicians of both persuasions aware of the importance of the IC&A contributions to our country’s wealth creation potential?” [Brett Simpson is President IICA.] Institute of Instrumentation, Control & Automation 1300 781 715 www.iica.org.au

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PACE ZENITH ONS I T A N I NOM SOON G CLOSIN

L I R P A 1 2012

AWARDS

MELBOURNE 14 JUNE 2012 The PACE Zenith Awards recognise companies and professionals who show innovation in engineering projects and technological excellence in one or more of ten industry categories. CATEGORIES: Automotive & Manufacturing Food & Beverage Machine Builder Mining, Minerals & Exploration Oil & Gas Power & Energy Management Lifetime Achievement Award Transport, Power & Infrastructure Water & Wastewater Young Achiever

HOW TO ENTER Download nomination kit at: www.pacetoday.com.au/awards

PROUDLY SPONSORED BY:

FOR MORE INFORMATION Contact: Madeline Prince Tel: 02 9422 2759 E: awards@pacetoday.com.au

SPONSORSHIP OPPORTUNITIES Contact: Tim Richards Tel: 02 9422 2818 E: tim.richards@reedbusiness.com.au

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