PACE - Process & Control Engineering - March 2014

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MARCH 2014 | VOL.67 NO.2

Post Print Approved PP100008186

INSIDE PACE

Mining

Automation

Water

Productivity gains are based on improvements to existing minerals processing operations

Risk-free solution helps manufacturer improve product quality

COHRAL produces effluent of higher quality compared with open lagoons

Non-intrusive Gas and Liquid Flow Measurement www.flexim.com

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CONTENTS

Publisher: Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor: Kevin Gomez Tel: (02) 8484 0976 Fax: (02) 8484 0722 Email: kevin.gomez@cirrusmedia.com.au Group Sales Manager: Tim Richards Tel: (02) 8484 0829 Mobile: 0420 550 799 Email: tim.richards@cirrusmedia.com.au

IN THIS ISSUE

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 Graphic Designer: Dave Ashley Email: david.ashley@cirrusmedia.com.au Production Co-ordinator: Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0722 Email: tracy.engle@cirrusmedia.com.au

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10 Technology Focus 12

Engineer’s Corner 19

Management 10

Case Study 16

Opinion 26

Process control ODVA outlines vision for manufacturers looking to maintain cost-effective and sustainable production capacity iOps boosts collaboration Integrated Operations Center creates more collaborative and effective organisations

Minerals processing CSIRO has used ultrasonic velocity profiling to help a company improve their solvent extraction settler performance Integrated automation After modernising its plant, an animal feed manufacturer gets a 7% production increase

Turn problem to profit Covered high rate anaerobic lagoon systems help agribusinesses clean up waste water while harvesting green energy Instrumentation Increased functionality will bring major productivity advances to process instrumentation

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Non-intrusive flow measurement in harsh, corrosive environments

MARCH 2014 | VOL.67 NO.2

INSIDE PACE

Post Print Approved PP100008186

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OFFICIAL MAGAZINE OF:

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Pa ge

Mining

THE FLUXUS F705 and G705 ultrasonic liquid and gas clamp-on flow meters allow for an inherently precise bi-directional, highly dynamic flow measurement of volume and mass flow rates of virtually any gaseous and liquid media – even at wet gas applications (up to a Liquid Volume Fraction of 5%) or liquid media carrying high contents of solids.

With the transmitter being ATEX, IECEx Zone 2 and FM Class I, Div. 2 certified – transducers for ATEX, IECEX Zone 1 and FM Class I, Div. 1 are available – it is also the ideal flow meter for hazardous areas.

Moreover, with its stainless steel enclosure (316L/1.4404) it is highly corrosion resistant and Non-intrusive Gas and 5 Liquid / 0Flow2Measurement / 2 0 1 4 , 1 0 : 4 9 : 3 5 AM especially suited for applications offshore.

Productivity gains are based on improvements to existing minerals processing operations

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Automation

Water

Risk-free solution helps manufacturer improve product quality

COHRAL produces effluent of higher quality compared with open lagoons

www.flexim.com

www.flexim.com

The Future of Manufacturing

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MARCH 2014 www.pacetoday.com.au 3

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COMMENT

WHAT’S ON

EDITOR’S MESSAGE

Remote operations take a step forward

EtherCAT Roadshow 25, 26, 27 March 2014, Melbourne, Sydney, Brisbane www.ethercat.org Configure and Maintain Industrial Control System Networks 9-10 April 2014, Brisbane training@innotech.com.au National Manufacturing Week 13-16 May 2014, Sydney www.nationalmanufacturingweek. com.au TUV – Functional Safety Course 20-23 May 2014, Perth www.hima.com.au

For daily updates visit www.pacetoday.com.au

Kevin Gomez Editor

Next Issue • Motors, Drives & Motion Control • HMIs & Rugged Systems • Wireless Technology • Process Control in Food & Pharmaceuticals

WITH instruments and automation systems demonstrating enhanced communications capabilities, there is increasing emphasis on remote operations. To date, the focus on operating remote industrial facilities was to maintain steady-state operations despite frequent disturbances.

Operators were doing whatever was required to keep the facilities running and meet production schedules in a safe and environmentally acceptable way.

Although some remote facilities still operate in this mode, the next-generation of remote facilities will not. Tighter production specifications and the need to maintain supply reserves, plus more stringent

process safety measures, cyber-security standards, and environmental regulations further challenge this dynamic environment, according to ARC Advisory Group.

The traditional hierarchical SCADA systems used to monitor and manage remote operations are evolving into a new generation of more flexible remote operations management (ROM) technologies.

Emerging technologies, such as FOUNDATION fieldbus for ROM (essentially an extended control LAN), will provide operations staff with tools that define precisely what is happening, what will happen, and if the current trajectory is leading to an unacceptable

result, what needs to change to achieve an acceptable result, thus providing the opportunity to take corrective action.

Interesting times ahead!

This month we are calling for your entries to the 11th PACE Zenith Awards.

Nominations close April 11, so hurry. There are eleven project and people categories available.

All finalists get two free tickets to the gala dinner which will be held on June 12 at the stylish ZINC in Melbourne.

Download your nomination form from www.pacetoday.com. au/awards kevin.gomez@cirrusmedia.com.au

Like us on Facebook and join the conversation facebook.com/PACEtoday

ROBOTICS

All-time-high for industrial robots in 2013 THE global demand for industrial robot demand substantially. Due to the relation with market and industrial robots reached an all-time-high of about rather weak development in the first requirements, accounting for product 168,000 units in 2013. three quarters, robot sales in Europe quality and competitiveness as well The International Federation of stagnated in 2013. as safe processes,” explained Arturo Robotics (IFR) estimates that in 2013 Between 2010 and 2013, the Baroncelli, IFR President. about 168,000 industrial robots were annual increase of global robot sales Joe Gemma, IFR Vice President, sold, 5 percent more than in 2012. was about 12 percent on average added: “Those of us in the industry are Robot sales to Asia rose considerably despite the critical economic situation not surprised by the growth as many due to strong demand from China, in some key countries. factors have contributed to the increase South Korea and other growing “One basic reason for the use of robotics worldwide, some of Asian markets. continuous growth in the use of which has been driven directly from the P 0 3fourth 1 4 _quarter 0 0 02013, _ M ethe t q u i p robotics 2 - is1its never 2 0 1ending 4 - 0 3 - 0 7 T 0 9 automation : 3 1 : 1 equipment 9 + 1 1 : manufacturers.”

0 0 InAthe start of recovery in the euro-zone pushed technological development in The software to work with and

run robots and automation cells has developed rapidly over the last few years and the ease of use has transcended into more applications under a very demanding and dynamic manufacturing landscape that would not have been tackled in the past. This has enabled manufacturers to provide products to the market quicker and with flexibility of variations to meet consumer demand and at the same time ensure the quality required and the performance demanded. www.ifr.org

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NEWS

FLOW

Liquid metal pump for micro-fluidics RMIT University researchers in Melbourne have developed the world’s first liquid metal enabled pump, a revolutionary new micro-scale device with no mechanical parts. The unique design will enable micro-fluidics and lab-on-a-chip technology to finally realise their potential, with applications ranging from biomedicine to biofuels.

Lead investigator Dr Khashayar Khoshmanesh from RMIT, said currently there was no easy way to drive liquid around a fluidic chip in micro-fabricated systems. “Lab-on-achip systems hold great promise for applications such as biosensing and blood analysis but they currently rely on cumbersome, large-scale external pumps, which significantly limit design possibilities,” he said.

“Our unique pump enabled by a

The pump is highly controllable, with the flow rate adjusted simply by altering the frequency, magnitude and waveform of the applied signal. single droplet of liquid metal can be easily integrated into a micro device, has no mechanical parts and is both energy efficient and easy to produce or replace.

Just as integrated micro-electronics has revolutionised the way that we process information – enabling the

development of computers and smart phones – integrated micro-fluidics has the potential to revolutionise the way we process chemicals and manipulate bio-particles at the micro-scale. This innovation shows that micro- and nanoscale pumping can be accomplished with

a simple system – a crucial advance for the field of micro-fluidics.”

The design uses droplets of Galinstan – a non-toxic liquid metal alloy comprised of gallium, indium and tin – as the core of a pumping system to induce flows of liquid in looped channels. When the alloy is activated by applying a voltage, the charge distribution along the surface is altered.

This propels the surrounding liquid without moving the Galinstan droplet through the loop, using a process called “continuous electrowetting”.

The pump is controllable, with the flow rate adjusted simply by altering the frequency, magnitude and waveform of the applied signal. The flow direction can also be readily reversed by reversing the polarity of the applied voltage. rmit.net.au

MANUFACTURING

AWARDS

Entering the PACE Zenith Awards?

NOW is your opportunity to be recognised for your contribution to automation, instrumentation and process control industries.

This is the eleventh PACE Zenith Awards event and we are expecting record numbers at the gala dinner in Melbourne on 12 June 2014.

The entry process is simple, and free; download an entry form from www.pacetoday. com.au/awards or email us at editor@pacetoday. com.au. The entry deadline is 11 April 2014, so hurry!

Nominations are now open for the 11th Annual PACE Zenith Awards 2014, to be held in Melbourne on Thursday 12 June 2014.

If you’re a supplier, nominating your customer is a great way to say ‘thank A total of 11 project and people awards will be up for grabs on the night, highlighting innovation and excellence in Australia’s community. or you’ for their business to showcase the unique application ofengineering your product All finalists will receive coverage in PACE magazine, on www.pacetoday.com.au and technology. associated social media platforms.

If you’re a team leader or business owner, adinner fantastic waywilltobeboost Finalists will also receive two entering free tickets to theis gala where the winners announced. staff morale and show off your company’s level of competence.

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ODVA outlines vision for process industries ODVA’s white paper, Optimisation of Process Integration, outlines a strategic vision for manufacturers looking to maintain cost-effective, sustainable production capacity in the process industries. The white paper (http://goo. gl/X3oqL5) is designed to help business and technical leaders in these industries define their future network architecture and plan for the efficient integration of their plant’s network infrastructure into existing business applications.

ODVA envisions an approach to the optimisation of process integration that is convergent, compatible, scalable and open for users and their suppliers. The approach will simplify the exchange of configuration, diagnostic and production data between field devices and higherlevel systems, such as supervisory control and data acquisition systems.

The approach also will enable plant asset management (PAM) and secure remote access of field installations.

This, together with the benefits and cost advantages of commercially available, off-the-shelf Ethernet and Internet technologies, will help

businesses improve productivity.

“In ARC’s vision for the plant of the future, Ethernet is integrated into process automation systems,” said Dick Hill, vice president and general manager, ARC Advisory Group. “The application of Ethernet technology to process automation promises to collapse these systems into a paradoxically simpler structure, while providing a solid basis for distributed intelligence with the elimination of artificial barriers to data and information.”

Katherine Voss, president and executive director, ODVA, agrees that industry will see a continued expansion of Ethernet and IP technologies in automation systems.

“The Optimisation of Process Integration leverages the prevailing trend of convergence in information and communication technologies used in industry and in business applications,” said Voss. “EtherNet/IP is a suitable technology to provide process industries with a unified communication solution from the field to the enterprise.” www.odva.org

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NEWS

FILTRATION

Low-cost water treatment process implemented in Victoria A LOW-cost water treatment process has been implemented at Rosslynne Water Filtration Plant (WFP) in Gisborne, Victoria. GHD has helped Western Water remove disinfection by-products from the source water at the WFP’s 35 ML/d capacity reservoir. This will result in greater utilisation of the local water supply and less importing of expensive water from Melbourne.

Michael Chapman, GHD’s Project Director, says, “This is an excellent example of how innovative thinking can help water utilities reduce costs and create additional value from their existing assets. This solution builds on GHD’s work with Western Water towards an integrated sustainable water supply strategy.”

The innovation was to dose Powdered Activated Carbon (PAC) at concentrations tailored to achieve the required removal of variable Dissolved Organic Carbon (DOC) levels in Rosslynne source water.

The PAC particles loaded with DOC are removed by the existing Dissolved Air Flotation process at the WFP. Running from May 2012 to January 2014, the project involved bench and full scale pilot testing, followed by full scale construction at the existing Rosslynne WFP. In addition, works to optimise the removal of manganese and to fluoridate water A D _ P Athe C treated E A MS F Ewere B _ implemented.

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Water utilities can reduce costs and create additional value from their existing assets.

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OPINION

EFFICIENCY

Save with intelligent pumps Industrial pumps consume between 25 and 50 percent of the total energy, writes James Whalen.

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NCREASING energy costs over the last few decades have put more pressure on companies across all industries to find more efficient ways to utilise energy. Reducing energy consumption reduces both input costs and CO2 emissions for industrial organizations.

The need to increase efficiency contributes to the gradual shift to consider total lifecycle costs, rather than just initial purchase and installation costs. Here, the energy consumption of an asset – whether or not it’s actually in use – represents a significant component.

Unfortunately, purchasers of industrial pumps have been slow to embrace this lifecycle cost approach and, instead, often still base their decisions on antiquated techniques that result in significant wasted energy. ARC Advisory Group research indicates that, by implementing modern intelligent pump systems, industrial plants could realise significant energy savings, while reducing their carbon footprint.

Major contributors to energy use

According to the US Department of Energy, industrial pumps consume between 25 and 50 percent of the total energy used by electric motors in industrial applications. This represents a huge expense; one that will only increase as energy costs trend upwards.

Expenditures on energy are one of the largest cost contributors to most industrial processes and plants.

From a lifecycle cost perspective, the purchase cost of a pump system represents just 10 percent of the entire cost. According to the US Department of Energy, after the initial purchase of the pump, the remaining cost breakdown is 7 percent for installation, 5 percent environmental costs, 3 percent for costs associated with the pump when not in use, 10 percent operating costs, 25 percent maintenance, and 40 percent for energy.

These data clearly reflect the huge 8 www.pacetoday.com.au MARCH 2014

costs-saving potential from implementing energy-saving intelligent pumps in place of conventional pumps.

Intelligent pumps improve efficiency

Today’s pump suppliers offer an array of features designed to improve energy efficiency. These include the addition of a variable frequency drive (VFD) that enables pump speeds to closely match the actual flow demanded at a specific time.

This means a pump can be ramped up at times of high demand and pulled back when lower flow rates are needed.

This saves energy and keeps pumps from working harder than they need to, extending pump life.

Many pumps now also come with embedded sensors that detect flow rates and can automatically vary the speed of a drive to maintain required flow rates and pressure.

This capability further improves the efficiency of a pumping system, decreasing the amount of energy required to meet pumping demands.

Based on physics-based affinity laws, reducing pump speed by just 10 percent (resulting in a minor reduction in flow rates); will reduce energy consumption by approximately 25 percent.

Another possible use of this technology is to link two smaller pumps, with one used to meet the demands of the lower flow rates and the second pump kicking in to boost pump capacity as required. This approach is ideal for a plant that only occasionally requires above-average flow rates.

Experts estimate that a system that automatically adjusts speed to match the required flow rates can reduce the overall energy consumed by a pump by up to 50 percent. Referring back to the lifecycle cost breakdown provided earlier in this report, we see that this can reduce total lifecycle costs by up to 20 percent; or twice the initial cost of the pump.

Slow to adopt intelligent systems

Despite the potential cost and energy savings, many industrial end users

have been slow to adopt the new technologies.

Most users still use the antiquated approach of selecting a pump that can meet the highest rate that will be demanded, resulting in a huge amount of unnecessary wasted energy over the lifetime of the pump.

ARC believes this resistance to implementing intelligent pumps is based partly on cultural resistance and partly on the slightly higher initial cost. However, in most applications, the slightly higher upfront costs of intelligent pumps are more than offset by the overall savings in lifetime costs.

Aside from the energy-saving benefits, intelligent pumping systems also provide the ability for users to remotely monitor the health of the pump.

Embedded sensors can measure leakage, vibrations, overheating, clogs, etc. and alert users to an issue long before the pump actually breaks to support predictive maintenance strategies and reduce unplanned downtime.

Certainly, the specific energy savings realised from adopting an intelligent pump system can vary greatly depending on the application and facility. In existing facilities, an energy audit of the current pumping systems can provide a helpful data point for evaluating the total lifecycle cost savings that upgrading to intelligent pump systems could produce.

Assuming that these cost savings outweigh the cost of implementing the new system, it should be relatively simple to build a business case for the upgrade.

[ARC Advisory Group analyst, James Whalen, joined ARC in 2013. Prior to joining the company, he worked as a product management and marketing intern with the Watson Marlow Pump Group, a peristaltic pump company servicing a wide range of industries. There, he was responsible for conducting market research as well as working on product updates and management.] www.arcweb.com

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BEHIND THE SCENES

iOps aims to boost collaboration The recently opened iOps is the global headquarters for Emerson’s automation systems and project services business, which helps customers safely, reliably and profitably operate facilities in industries such as oil and gas, refining, chemicals, power, life sciences, food and beverages, and metals and mining, writes Hartley Henderson.

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HE recent launch by Emerson Process Management of its US$70 million Integrated Operations Center (iOps) in Austin, Texas, provides facilities aimed at creating more collaborative, effective organisations.

This real-world lab is designed to assist customers to see the future and then work with Emerson iOps consultants to plan a customised path forward. It is a facility where customers can explore new ways of managing remote operations, and benefit from easier collaboration by experts located anywhere in the world.

At the heart of the facility is the iOps Command Centre which offers the latest in automation and audio visual technologies. It is here that different business functions, such as production operations, maintenance, logistics, and commodities trading are brought together into a collaborative control room environment.

Pervasive sensing allows monitoring of data from process and non-process sensors throughout the enterprise. It is the foundation of the enterprise knowledge networks that not only apply to the process but also the business.

Integrated videoconferencing and IP video cameras provide visibility into remote operations, and dashboards are used to monitor the health of assets around the world. Connections to subject matter experts across Emerson allow the iOps team to have access to the right knowledge to optimise control system performance and reliability of assets including pumps, compressors, instruments, valves, and the DeltaV digital automation system.

In this way, customers are provided with a true-tolife look at potential technologies and work processes as they try to optimise the reliability and performance of their own operations.

The Command Center features a Barco OL-series LED-lit 30ft by 6ft rear projection video wall.

With one click, the content across all screens in the Command Center can change, instantly transforming the environment from an integrated oil and gas production operation to a refinery, to a petrochemical complex, or a pharmaceutical plant.

In addition to providing a virtual operations environment, the Command Center also features a process skid with an oil and water mixing and separation process. This is controlled and monitored almost entirely by Emerson instrumentation, including Fisher valves and digital valve controllers, Rosemount® transmitters, Micro Motion Coriolis flowmeters, and CSI wireless vibration transmitters.

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With fewer workstations there is a smaller overall footprint which means faster set-up and teardown and easier maintenance DeltaV control system

The skid’s pumps are controlled by Emerson’s Control Techniques variable speed drives which interface with the DeltaV control system through digital bus technologies including Foundation Fieldbus, Profibus DP, AS-I, and DeviceNet as well as through HART and WirelessHART. HART instrumentation is wired to field–mounted enclosures with all aspects of DeltaV’s Electronic Marshalling solution, including standard CHARMs, intrinsically safe CHARMs, and the newest product, DeltaV SIS Electronic Marshalling, which is used for safety instrumentation systems, fire and gas systems, and burner management systems.

Emerson’s DeltaV Product Manager for Advanced Control and Virtualisation Solutions, John Caldwell, says that the iOps Center’s process skid is supplemented in part by process simulation software from another of Emerson’s partners, Mynah.

“Mynah’s MiMiC software provides high-fidelity process simulation of distillation columns and other unit operations, and allows for the use of the DeltaV systems’ advanced control applications to demonstrate optimised model predictive control, neural networks, and other control strategies,” Caldwell explains.

“UPS power to the DeltaV system and process skid is supplied by Emerson Network Power, and advanced diagnostics of the UPS integrate with DeltaV and Emerson’s AMS Suite diagnostic software applications through a Profibus interface.”

iOps Data Center

All systems and content in the iOps Center are virtualised and run in server clusters in the iOps Data Centre. Content from these systems is then served to the various rooms in the iOps Center as well as Emerson facilities around the world.

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BEHIND THE SCENES

“The computing power of the iOps Data Center is provided by two other partners in the Center – Dell and Intel. Dell servers (powered by Intel chips), switches, and storage area networks (SANs) are used to create server clusters at network levels 2 and 3. From there, Dell/Wyse thin clients are used where required throughout the facility to connect to the virtual machines in the Data Center,” Caldwell said.

“The virtualised level two system is powered by DeltaV Virtual Studio which provides a purpose-built, easy to use management interface for virtualised DeltaV systems. This level 2 cluster runs four different DeltaV systems simultaneously – a total of approximately 30 DeltaV stations.

“Each of these four systems is focused on a different industry – oil and gas, refining, chemicals, and life sciences. The systems are connected together through DeltaV inter-zone servers so that they can seamlessly serve data.”

The virtualised level 3 system is powered by VMWare. Caldwell explains that on that cluster, Emerson’s Syncade software is used to manage batches and recipes in the DeltaV system, to provide document management, and to procedurally automate manual tasks, such as batch material additions, safety proof testing, and loop commissioning and check out.

“This level 3 cluster also hosts Emerson partner platforms, such as OSI PI, which provides an enterprise historian and federated data collection across other sites.

Meridium provides asset performance management software that manages and monitors all facets of reliability across assets such as pumps, compressors, and

the instrumentation for multiple plants.

“C3 Global’s Amulet software brings together data from the historian, event databases, and enterprise systems to provide advanced analytics and web-based visualisations.”

In addition to providing a virtual operations environment the Command Center also features a process skid with an oil and water mixing and separation process The iOps Center also features collaboration rooms, with each room equipped with integrated videoconferencing. By tapping an icon on the iPad, the video cameras drop from the ceiling, microphones rise from the tabletop, the room lighting adjusts, and the shades lower around the building perimeter.

From these rooms, a global network of subject matter experts is pulled in on demand to work with Emerson’s customers in helping to solve their toughest problems.

Virtualisation benefits

Caldwell points out that there is a range of benefits in moving from traditional hardware to an integrated virtual platform.

“Independence of hardware and software is provided, and the use of virtualisation gives greater flexibility, productivity improvement, lower total cost of ownership, higher availability, and effective disaster recovery,” he said.

“With fewer workstations, there is a smaller overall footprint which means faster set-up and teardown, and easier maintenance.”

[Hartley Henderson attended the iOps opening in Texas as a guest of Emerson Process Management.] www.emersonprocess.com.au MARCH 2014 www.pacetoday.com.au 11

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IN FOCUS

Sound developments improve minerals processing CSIRO has used ultrasonic velocity profiling to help a company improve their solvent extraction settler performance and reduce their operating costs.

By Keith Barnard.

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LTHOUGH one might think that mineral processing plants are all the same, they are not. They differ markedly depending on a range of factors including the element being recovered, the type of orebody in which it comes and the impurities present.

Each mineral processing plant is in essence a combination of different unit operations that together achieve the desired metal recovery. But while many unique challenges are faced by

each plant operation, the challenges faced by specific unit operations within those plants are similar throughout the industry.

One of the key steps in minerals processing is solvent extraction (SX), which is used for the separation, purification and recovery of a range of metals. There are a number of production challenges faced by operations and one of the key issues is costly reagent loss.

With the support of industry,

CSIRO has developed a multi-pronged approach to improve the operating and production efficiency of SX unit processes, helping companies make significant cost savings – especially on reagent loss.

CSIRO researchers are combining chemistry, small-scale physical modelling and advanced computational fluid dynamics (CFD) modelling with a variety of measurement tools and probes to identify operational problems and come up with technology solutions.

Figure 1: (L) Velocity field and streamlines in organic layer at 100 mm below surface as measured on plant using UVP probe. (R) CFD simulation of corresponding velocity vectors.

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Intelligence is the big differ difference

The key to success can be found in the relentless quest to enhance production efficiency while ensuring the best approach to health, safety and the environment.

Our unique combination of equipment, services and intelligence ensures success for our customers in the mining, construction, oil and gas, and other process industries.

Our focus is on constant development – on more intelligent solutions that make a big difference.

For more information, please contact your Metso representative as below: Perth: 08 9420 5555, Brisbane: 07 3623 2999, Sydney: 02 8825 1600 Email : minerals.info.ap@metso.com, website : www.metso.com

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IN FOCUS

The work is helping industry to improve their operational performance using both intermittent analysis and by developing analysis probes amenable to in-line installation.

SX and reagent loss

As a unit operation, solvent extraction (SX) relies on the mixing and subsequent separation of immiscible water solutions and organic (kerosene)based solutions. This is typically performed in a series of mixer-settlers by continually pumping the two solutions into a mixing chamber (box) which then overflows into a larger, non-agitated container (the settler) where they are allowed to separate via gravity before exiting as two separate streams at the other end of the settler.

Besides kerosene, the organic solution contains a reagent (i.e. extractant) which, under suitable operating conditions, is capable of selectively extracting metal ions and yielding a solution free of other metal impurities and therefore amenable to further processing, such as electrowinning.

While the metal transfer process from the water solution to the organic solution, or vice versa, is achieved by the mixing step, the settling stage is also very important and is required to separate the two liquid phases as completely as possible before moving on to the next stage.

The organic reagents used in SX are expensive, and by necessity the organic solution containing these reagents is continually recycled through the extraction and stripping stages.

Inevitably, some of the organic solution is lost via entrainment and dissolution in the water-based solution, and this constitutes an ongoing financial cost in terms of replacing it, as well as the cost of reducing the impact of organic contamination in downstream processes and the environment.

There are three opportunities to minimise reagent loss: 1 improve settler flow patterns to minimise recirculation and maximise the time available for separation of the two phases 2 facilitate better coalescence in the settler 3 minimise ultra-fine droplets forming in the mixer, as these separate more slowly than larger droplets in the subsequent settling stage.

14 www.pacetoday.com.au MARCH 2014

Figure 2: Revised settler design with three picket fences: velocity vectors at 0.4m above bottom.

Improving SX settler performance

Flow patterns and dis-entrainment behaviour in settlers can be affected by a variety of factors. For example, improvements in settler performance can be achieved by inserting customised ‘furniture’ such as picket fences or various media like Raschig rings to facilitate coalescence.

An onsite assessment of any settler design modification, including general maintenance, can be achieved by comparing organic entrainment losses before and after the completion of a particular modification.

However, this approach only provides an overall outcome, not detailed information regarding specific effects such as the flow patterns within the settler.

Although laser-based techniques such as Particle Image Velocimetry (PIV) and Laser Doppler Velocimetry (LDV) have been used to assess fluid flows in

CSIRO’s calculations showed that a revised design would reduce early exiting of fluid and could improve operational performance laboratory-based SX systems, they are restricted to analysis in transparent (for the laser) liquid systems, and as such are not particularly suited for analysis in most or all commercial SX systems.

In contrast, a key CSIRO development was the world’s first adaption and application of ultrasonic velocity profiling (UVP) enables flow patterns to be measured in various commercial SX operations.

Importantly, mapping flow patterns before and after furniture modifications allows specific and detailed effects to

be readily observed. UVP is enabling operators to make informed decisions regarding circuit operation and furniture installations, so that they can improve settler designs and reduce reagent loss.

For example, CSIRO worked with Freeport McMoRan at their Morenci site where they applied the UVP technique to observe the fluid flow behaviour in their settlers. Using this information, the company modified the internal furniture configuration in their SX settlers to change their process flow patterns and enable them to meet their production targets.

As a result, Freeport McMoRan was able to reduce reagent loss by 60 per cent, resulting in significant operational cost savings.

This technology and expertise is currently unique to CSIRO and is performed manually by skilled researchers on a site by site basis.

The technique’s success in various one-off investigations, in addition to Freeport’s experience, have proven its applicability to monitor flow patterns in industrial SX settlers. However, it only enables a snapshot of flow pattern behaviour to be obtained.

There is the potential to automate the UVP process via permanent or semipermanent installation of an array of UVP transducers wired-up to a central control room. This would provide plant operators with information to ascertain flow behaviour in their settlers and, by comparison with historical data, quickly identify when problems, such as blockages of picket fences, adversely affect operation. CSIRO is currently looking into this exciting development.

CFD modelling of flow patterns

The knowledge derived from UVP probes can also be coupled with advanced CFD modelling to create simulations of altered settler configurations to make further design improvements.

CFD simulations are only as good as the assumptions upon which they are based, so the ability to continually validate and improve the CFD model by comparing it with real flow data from the UVP instrument has resulted in a powerful predictive tool capable of assessing the impact prospective furniture modifications have on operations.

At another commercial operation, CSIRO investigated fluid flow in a

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IN FOCUS

settler through onsite measurements and CFD. Reasonable agreement was found between measurements and CFD simulation results (Figure 1). It was found that the flow pattern of the existing design was sub-optimal, with substantial short-circuiting and various regions of recirculation evident.

Such flow phenomena are expected to impact negatively on the goal of maximising solution separation and therefore minimising operational costs and the issues arising from high residual entrainment.

To improve this, additional CFD simulations were performed to investigate whether modifications to the internal settler design could improve the flow pattern.

A series of modifications were assessed, primarily being changes to the picket fences, such as the number of pickets, the gap width between pickets, the positions of the fences and the number of fences.

CSIRO’s calculations showed that a revised design would reduce early exiting of fluid and could improve operational performance.

The flow pattern for one alternative design containing three picket fences is illustrated in Figure 2.

For this design, a more uniform flow field was obtained, suggesting such a modification of the actual settler would be beneficial. This CFD-based interrogation approach enables various designs to be relatively cheaply and quickly explored without the need to interfere with operational activities, in contrast to what would be required for actual physical modifications at the operating plant.

Incremental improvements

Large productivity gains in the minerals processing industry are generally based on incremental improvements to existing operations, as all these add up to substantial sums of money.

In terms of SX operation, the capabilities developed by CSIRO over the past few years – in particular the combination of in situ flow measurement and CFD capabilities – has opened up the opportunity to make substantial improvements in SX settler design.

This has been achieved with the support of industry through multisponsor projects, where industry sponsors share the costs of research

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Commercial solvent extraction settler with picket fence.

Large productivity gains in the minerals processing industry are generally based on incremental improvements to existing operations

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Evo Foxboro

Maintain

Operate Manage

but benefit wholly from the valuable outcomes.

A recent project was sponsored by nine industry partners and is moving on to the next phase where CSIRO will develop and refine concepts, CFD capabilities and analysis probes for use in settlers.

CSIRO is also planning to deploy these and other instruments to investigate how to improve the mixing stage of SX. This is anticipated to deliver further productivity benefits for the industry.

[For more information about CSIRO’s SX process developments or to access CSIRO expertise, contact Keith Barnard on 08 9334 8071 or keith. barnard@csiro.au] [Keith Barnard is a CSIRO solvent extraction expert.]

08 9334 8071 keith.barnard@csiro.au MARCH 2014 www.pacetoday.com.au 15

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BEHIND THE SCENES

Feed manufacturer reaps rewards of totally integrated automation After modernising its manufacturing plant, an animal feed manufacturer has achieved a seven percent increase in production while reducing its energy consumption by two percent.

B

ASED in Upper Swan, Western Australia, Thompson & Redwood has been providing local farms, studs and stockfeeders with quality animal feed for over a quarter of a century.

In this time, the plant has served the farming community well, providing a regular supply of essential animal supplies. But over the many decades of repetitive action, the plant has certainly seen better days.

Thompson & Redwood Projects & Operations Director, Henry Little, realised the need to upgrade his plant in the face of increasing operational and industry pressures.

“Over the years, we’ve noticed a decrease in the number of technicians that are familiar with our unique system which has led to massive downtime issues and loss of production during equipment failure.

“In addition, with changes in the food safety regulations, we are now required to trace back any batch of product for quality assurance, which our existing system was not capable of,” explained Little.

A hungry for change

Siemens Solution Partner, AP Automation, was engaged to come up with a solution that would see the plant grow in line with its modern requirements, become more efficient, while being robust enough to handle the repetitive grinding and batching functions.

“The Thompson & Redwood plant was experiencing the typical growing pains of a facility this age,” said Andrew Phan, AP Automation’s Managing Director, upon reflection of his initial visit.

“Due to its obsoleteness, we couldn’t re-use any of the plant’s existing equipment, which was PC-based and had limited visualisation and diagnostic abilities – all very common of technologies from 20 to 30 years ago,” Phan continued.

With the challenge ahead of him, the Siemens Solution Partner devised a “risk-free solution that would help Thomson & Redwood improve product quality and reap the benefits that a modern control system offers.

Standardisation key to plant flexibility

The strategy that AP Automation came up with was based on the use of generic applications, allowing Thompson & Redwood to quickly and easily adapt to any grinding or batching application required.

With a growing number of products including 25kg and 40kg bags of feed for poultry, horses, sheep, cattle and birds, generic software applications were used to 16 www.pacetoday.com.au MARCH 2014

An overview of grinding process.

Manufacturing has had to overcome the challenge of providing more and more product lines in smaller quantities to meet the diverse consumer needs allow Thompson & Redwood the flexibility to quickly change from one production line to another, in a simple and easy-to-setup way.

Recognising that Thomson & Redwood is a small business with no ‘deep pockets’ to fall back on, the generic software applications were not just for the sole purpose of plant flexibility in its current operations.

These generic software applications will now provide Thompson & Redwood with the flexibility to cost-effectively upgrade the facility when required, thus future-proofing the manufacturer against any business changes down the track.

Adding to its generically-orientated game plan, AP Automation also standardised on the plant’s hardware components thereby allowing for very little adaptation for various applications.

“The hardware controls for the grinding and mixing

plant comprises of a S7-300 PLC with integrated Ethernet port connected to WinCC SCADA and a field programming unit over Profinet,” Phan explained.

“Over the same Profinet hangs the distributed inputs and outputs (I/O). The field sensors and actuators are connected to the I/O over industry standard Profibus and care has been taken to ensure that industry standards are used so that upgrades to the plant can be painless in the future,” Phan continued.

Phan also explained that the new active front end drive implemented as part of this upgrade would achieve energy savings due to the reduction of harmonics which would result in virtually no energy losses.

Making things right

The Siemens’ Totally Integrated Automation concept covering all aspects of industrial automation, was the foundation supporting AP Automation’s successful design, and was developed to meet the pressing needs of many manufacturers alike.

Totally Integrated Automation (TIA), is the name Siemens gave to efficient interoperability of all automation components. The open system architecture covers the entire production process and is based on the consistent presence of shared characteristics: consistent data management, global standards, and uniform hardware and software interfaces.

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BEHIND THE SCENES

The batching software is designed to work with any number of raw materials and an unlimited number of recipes which makes it adaptable to any grinding and batching application TIA delivered risk-free integration of hardware, user-friendly software, visual diagnostics for proactive maintenance and fault detection as well as automated reporting, to name a just a few benefits.

Phan has utilised TIA technology to the benefit of his customers for many years, helping many clients across various industries make the right decisions for the future of their businesses.

“As an engineering company, we have the freedom to integrate any equipment into our designs as we see Silos hold animal feedstock. appropriate and we’ve found TIA to consistently bring results.

Siemens has conducted studies that have shown “I’m especially pleased with TIA’s diagnostic ability, TIA to have assisted in reducing hidden life cycle costs, which I believe to be superior in the industry, as this has amounting to up to 80 percent of the total project costs. assisted many of my clients in preventing a lot of potential Little could not be more pleased with the choice of breakdowns and while explains AD_ PA C issues E D WY M maximising A R _ 1 2 .their p duptime f P a g etechnologies 1 1 0 applied / 0 1 in / 1his2new , look 9 : plant 4 0 and AM and most importantly, their profits,” reported Phan. how this new system has transformed his production.

“The application software is quite user-friendly which has minimised the costs in training our operators. It picks up the recipe from the WinCC database and displays it on the Human Machine Interface (HMI) screen.

The operator can then alter the recipe parameters

MARCH 2014 www.pacetoday.com.au 17

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Decentral Periphery

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Totally Integrated Automation. if required, depending on the process order and availability of raw materials. Once the operator is happy with the recipe, they release it to the system which automatically assigns the batch number and starts production. The operator is then able to monitor the entire production process as it is happening. “In terms of the batching, reports are automatically produced and exported to MS Excel. The batching software is designed to work with any number of raw materials and an unlimited number of recipes which makes it adaptable to any grinding and batching application. It also displays the status of the batch on the overview screen,� explained Little.

Real solutions for real needs

In an age where consumer choice prevails, manufacturing has had to overcome the challenge of providing more and more product lines in smaller quantities to meet the diverse consumer needs – all while retaining of economies of scale.

This, tied with the ongoing economic climate of local resource costs and until recently, a very strong Australian dollar, has created a lot of pressure on our manufacturing sector to remain profitable. In order to continue operating in Australia manufacturers need to modernise their industrial production even more – to increase their productivity, efficiency, quality and digitalisation.

Siemens, strongly believes that industry still has a key role to play in the Australian economy, driving research into technologies to shape the Future of Manufacturing and make things right.

The new active front end drive implemented as part of this upgrade would achieve energy savings due to the reduction of harmonics which would result in virtually no energy losses For Thomson & Redwood, the key selling point for the Siemens solution was its ability to adapt to any grinding or batching application with ease. The solution was based on reusable, reproducible and repeatable software libraries which can be tailored for any application and consequently provide Thomson & Redwood with the flexibility to produce various product lines efficiently.

Combined with standardised hardware and all the automated features of a modern control system, Thompson & Redwood has reported an increase of up to seven percent in production efficiencies since commissioning of the plant upgrade. “The improvement in efficiencies is due to fine tuning of the new system and reduced down time. And, as a result of these efficiencies, we’ve also seen energy savings of two percent which is a bonus given the rising cost of energy,� said Little. www.siemens.com.au

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IN FOCUS

Turning problem to profit Advanced anaerobic covered high rate anaerobic lagoon system turns problem to profit by helping agribusinesses clean up waste water while harvesting green energy.

A

COST-EFFECTIVE way to simultaneously increase the quality of waste water produced by agribusiness while disposing of an expanding odour pollution issue is being deployed to assist crop and livestock operations achieve higher environmental standards.

The COHRAL technology of Global Water Engineering (GWE) involves a Covered High Rate Anaerobic Lagoon that uses concentrated anaerobic bacteria to digest 70 percent of the organic matter COD (chemical oxygen demand) in waste water to produce effluent of far higher quality than open lagoons.

“Even higher water quality standards – exceeding 90 per cent COD removal and up to 99 per cent in some instances – can be achieved by using GWE anaerobic and complementary technologies contained in totally enclosed tanks, or reactors, making it suitable for discharge in surface waters,” says Michael Bambridge, Managing Director of CST Waste Water Solutions who represent GWE anaerobic wastewater technologies in Australasia. GWE has been offering clean water and green energy solutions for more than 35 years.

COHRAL technology – including the first example in Australia now being engineered by CST Waste Water Solutions – eliminates many of the odours associated with open lagoons often used in meat, dairy and crop waste processing. These are increasingly leading to environmental protests and land use conflict as urban expansion and rural businesses operate in greater proximity to each other.

“Another major benefit of covered anaerobic lagoons, and of totally enclosed anaerobic reactor systems, is that the methane biogas produced within them by the anaerobic process can be collected and used to feed steam boilers and processing plant, replacing fossil fuel. This has been demonstrated in many GWE applications worldwide to repay the cost of an anaerobic system in as little as a year or two. It can then to go on to save thousands and millions of

Biogas is used to heat boilers. dollars in fossil fuel costs over succeeding decades,” said Bambridge.

The first COHRAL installation in Australia, to be employed at a meat processing and packing plant, will feature reuse of the biogas in the boiler.

Closed lagoons not only prevent methane escaping into the atmosphere (where it is many times more damaging to the atmosphere than C02 emissions) but also generate energy, rather than being heavy consumers of energy in processing and oxygenation.

“Open lagoon wastewater treatment systems were popular with industry because they were simple, cheap and easy to operate, allowing an ‘end of pipe’ solution to wastewater issues.

They were, in effect, often used as dumps for problems occurring in processing, not recognising the loss of a valuable recoverable product – energy,” says Bambridge.

A covered high rate anaerobic lagoon uses concentrated anaerobic bacteria to digest 70 per cent of the organic matter “However, these systems are now being recognised by governments worldwide for their environmental downsides, including their poor ability to control algae and suspended solids in warm weather and poor efficiency in removing pollution load.

Covered lagoons

COHRAL installations represent an advance over open lagoons and are suitable for solutions involving less technology-intensive applications that

allow a long process residence time and where adequate space is available. They are a cost-efficient first step toward totally enclosed reactor type anaerobic technologies.

COHRAL anaerobic lagoons consist of two zones, with the complete surface of the lagoon being covered with an influent distribution system The first and largest zone receives the major part of the incoming wastewater.

This reaction zone is where the anaerobic digestion occurs.

The second, smaller part of the lagoon serves as a post-digestion and pre-settling zone where a partial clarification of the effluent wastewater takes place. Settled sludge collected in this zone is pumped back to the inlet of the lagoon Part of the anaerobic effluent is recycled back to the lagoon. The remaining effluent of the lagoon flows MARCH 2014 www.pacetoday.com.au 19

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IN FOCUS

by gravity towards complementary technology such as the GWE proprietary SuperSep-CFS separation technology being used in the first Australian installation.

No additional mixing facilities are required in the anaerobic lagoon. The influent distribution system acts as a hydraulic mixing system, converting a standard low load/low efficiency lagoon into a COHRAL system with increased efficiency.

Floating membrane

Safety is also integral to COHRAL system. Each anaerobic lagoon is covered by a special floating membrane to retain the methane produced. A typical feature of GWE’s COHRAL system is the operation at zero biogas pressure (-1 to +1 mbar range). A sensitive membrane level measurement system controls the speed of a biogas extraction fan bringing the gas at 20 mbar to go to the flare.

Compared to “inflated” single membrane covers, the risk for leaks is virtually zero.

Simplicity also extends to the SCADA computer control system typically employed with COHRAL technology. All indications and alarms, as well as reporting on the daily operation of the plant, and “trending” can be done by a SCADA computer system. All motor start/stop as well as auto/manual functions can also be controlled from the SCADA computer.

A simplified flow sheet can be displayed on the SCADA computer’s colour screen, featuring all measurements (continuously updated) and indicating operating motors. Alarms can be indicated by a colour change to

Open lagoons pose risks. red of the corresponding measurement or indication. An external acoustic alarm can also be incorporated.

Future of uncovered lagoons

The character, toxicity and quantity of agribusiness contaminants presenting problems today are far more complex than those that presented challenges in the past, with pathogens, nutrients and highly publicised problems such as bluegreen algae spilling into the environment from lagoons and toxins building up over decades.

COHRAL technology eliminates many of the odours associated with open lagoons.

20 www.pacetoday.com.au MARCH 2014

“And this is happening as population growth is taxing reserves of shared community resources, such as clean water, clean air and land for urban development and sustainable agricultural uses,” says Bambridge.

“In a highly urbanised society such as Australia – and one which values and markets its clean/green credentials – conflict between land uses will grow without community-corporate partnerships to resolve issues.”

Food and beverage processors will be in the front line of change, along with primary processors, including meat and dairy processors, as well operators of any industrial manufacturing or processing plant that draws water from its surroundings and returns water to the environment.

Good solutions do not have to be extortionately expensive and can be staged: ¬ A first step in many instances can be taken by covering lagoons and incorporating anaerobic processes with properly engineered feed and recycle systems, such as those in the COHRAL process. ¬ A second progressive step can involve the use of tanks to contain anaerobic and other processes, minimising land use, reducing plant footprints and providing high security against leaks

and groundwater contamination.

Anaerobic processes can also be more closely efficiently controlled in such close environments, optimising water purification and green energy production. ¬ A third optimum stage can be the eventual incorporation of the most advanced anaerobic technologies into sealed tank environments, such as GWE’s RAPTOR treatment system for organic residues, for example, which can convert almost any organic residue or energy crop into biogas, valuable electricity or heat.

Anaerobic digestion facilities have been recognised by the United Nations Development programme as one of the most useful decentralised sources of energy supply, as they are less capitalintensive than large power plants. They can also benefit local communities by providing local energy supplies and eliminate the need for large and often smelly and environmentally challenging settling lagoons.

“It’s just sensible corporate risk management really for any company CEO or Director to look at their options, to anticipate the problems lagoons may be creating now and certainly as we move into the future,” says Bambridge. www.cstwastewater.com

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IN FOCUS

PACs for data analysis and energy management With programmable application controllers, companies have access to valuable information that can help shape their models for energy management, writes Shaun Loesch.

A

S ECONOMIC trends, competitive forces and commodity price fluctuations continue to produce challenging operating conditions for industrial manufacturers and producers, there is an increasing focus on raising the productivity of existing assets and resources and minimising reliance on CAPEX. One way is to make better use of the vast amounts of information which exists within their plants and operations.

A key driver of operational costs is

energy usage, which can be difficult to accurately measure and consolidate as energy measurement information is available from a large number of sources – such as power meters, smart devices and process instruments. All of these sources of information need to be brought together, combined and analysed in conjunction with process data in order to achieve optimum and effective energy management.

High quality data is obtained from connected devices and instrumentation, and therefore the associated control

system needs to provide open interfaces to each of these different devices, with the ability to time stamp (to milliseconds) the data being collected (both electrical and process data).

Current levels of energy management are mostly focused on energy consumption and looking at peak demand or power factor. These primary measures need to be considered in order to address processes that have the most direct impact on energy consumption.

Beyond this, there is deeper analysis which should take place based on energy

data that provides predictive rather than reactive information about the process.

To complete this analysis there needs to be increased and simplified access to the information that is available within smart devices and power meters.

Role of PACs

Although the information available from smart devices, instrumentation and meters is growing, these sources are typically located on proprietary networks or open networks dedicated for Programmable Application Controllers (PAC).

Modicon M580 is world’s first ePAC SCHNEIDER Electric’s Modicon M580 is said to be the world’s first ePAC (Programmable Automation Controller) which is based entirely on Ethernet.

“The heart of Modicon M580 is the SPEAr (Structured Processor Enhanced Architecture) microprocessor that embeds inside the controller standard unmodified deterministic Ethernet and applies it to all communications, including all the way to the hardware connection on the backplane,” said Antonio Chauvet, Research & Development Director at Schneider Electric.

He further explained, “The result is an outstanding level of transparency and performance, without any need for manual configuration of each connected device – the SPEAr technology applies Ethernet communications to the field bus, control bus, and internal backplane bus, and, consequently, to all the connected equipment and modules.

“Ethernet is also automatically applied to every device in the network, such as electrical distribution, low-voltage boards, and energy management functions – to form a complete and open system.”

Marc Lafont, Marketing Director for Modicon M580 at Schneider Electric, said, “The ultra-powerful 600MHz ARM dual-core processor is the digital engine inside the M580. It delivers an extremely high level of computing power and connectivity, enabling us to build safety features right into the controller and enhance its resistance to cyber threats.

22 www.pacetoday.com.au MARCH 2014

The Modicon M580 ePAC has Ethernet built into its core.

In addition, with integrated Change Configuration on the fly, plant teams no longer need to stop their process to add a drop or module, change architecture, or even modify the application.”

Upgrading to Modicon M580 is possible without additional investment in wiring, software development, or training. Based on the Modicon X80 range that includes the widely acclaimed on Modicon M340 controllers, M580 extends processing and architecture capabilities.

M580 also allows compliancy with Xbus communications of Modicon Premium, meaning that depending on the current system needs, users can easily switch between the different controller sizes in the Modicon range without changing their I/O racks and cabling.

Developed applications are preserved in the Unity Pro configuration software and remain fully operable with only minimum adjustment. goo.gl/xnOkHq

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IN FOCUS

These networks ensure that appropriate priority is given to the There needs to be increased and simplified access to control messages that enable effective the information that is available within smart devices process automation. This also forces engineers to select a subset of data and power meters required for energy management and copy it into the PACs in order between analysis applications and the to transfer a set of data to energy functions and services which support: smart devices, reducing any unnecessary management and other systems. This ¬ Secure and efficient process loads on the controller, which can dilute replicated data is often limited in its automation the available data. scope as it is not transparently collected ¬ Ethernet transparency, distributed To obtain the various multiwithin the PACs Ethernet scope. intelligence disciplinary functionalities needed to It has become increasingly apparent ¬ Links with business applications run an operation, process end users in today’s manufacturing and process ¬ Web integration require secure, reliable interoperability technology architectures, that the role ¬ Interoperability across their automation products and of the PAC has been extended beyond ¬ Device communication using infrastructure. As a hub for both realjust monitoring and control. It is now Ethernet and web standards time control and information, modern responsible for handling increased Benefits of ePACs PACs benefit from being designed with connectivity to a larger number of This evolution to the ePAC provides an open Ethernet backbone to optimise devices and the management of the features that enable process oriented connectivity and communications, large amounts of available data and companies to unlock large amounts of increase bandwidth, and provide a high information. In order to meet this automation and energy management level of security. increased responsibility a new generation data for big data analysis, without This enables companies to now move of PAC is required. compromising the control focus required. large volumes of data and information The new generation of ePAC (Ethernet enabled PA0 3 1 4 _Programmable 0 0 0 _ PLC 1 2It 0also 1 4absolves - 0 2 transfer - 2 8 Trisks 1 2by: 4 2 : 2 from 5 + 1the 1 various : 0 0 connected devices allowing a direct Ethernet connection found across their operations. This data Application Controller) implements

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is moved to the higher level applications and systems used to aid visualisation, analysis and ultimately the capability to make informed efficiency decisions. At the centre of this technology architecture is the Ethernet enabled PAC, or ePAC. The increased visibility of data stemming from their operations allows companies to critically analyse their energy outputs and implement appropriate measures to reduce them.

With the popularisation of big data and the virtualisation of companies’ operational applications, ePACs can provide a direct and vital link for large quantities of data gathered in everyday operations and the programs that are used to translate and anaylse this information.

The end result is that manufacturing and processing companies have access to information that can help shape their models for energy management, and ultimately maximise asset performances.

[Shaun Loesch is PAC Solution Manager, Industry Business, Schneider Electric.] www.schneider-electric.com.au

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SPOTLIGHT

7best of the

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

Quick connect option saves time

Direct insertion viscosity and density meter

Michell Instruments has added a fast connection option to its Easidew PRO I.S. dew-point transmitter to make commissioning and maintenance in locations that are difficult to access as simple as possible. The option was added to the range after Michell had worked with a customer in the Middle East to provide a solution where the Easidew PRO I.S. had to be fitted in an inaccessible, dark location. Under these circumstances, the standard conduit connection would have been difficult to work with. Michell’s solution – to adapt the standard Easidew PRO I.S. to include a fast connection – enabled the company to easily fit the dew-point transmitter in the required location. The connector is IP65 rated and suitable for installation in hazardous, process locations. The Easidew PRO I.S. provides fast, accurate dew point measurements from -100 to +20°C dew point, and is capable of measuring moisture in hydrocarbon liquids as well as in gases. It is certified

by ATEX for use in hazardous area zone 0, as well as for use with galvanic isolators.

The Micro Motion Fork Viscosity Meter is the next generation of the Micro Motion 7827 and 7829 direct insertion viscosity and density meters. Incorporating the same rugged and reliable tuning fork design as its predecessors, the Fork Viscosity Meter is built to tackle demanding process applications such as oil fired heater combustion control, HFO blending/production and pump protection. In applications where accurate, fast-response viscosity and density monitoring is required, the direct insertion Micro Motion Fork Viscosity Meter is a suitable choice. The meter helps solve problems customers face on a daily basis, such as reducing oil fired heater combustion emissions, minimising cutter-stock usage in HFO blending and reducing contamination risks on multi-product pipelines. The meter incorporates a hazardous area approved head-mounted transmitter that has the flexibility to connect to control systems via a range of digital and analog protocols. Because it supports 4-20mA, HART, WirelessHART, Foundation fieldbus and RS485 Modbus, system integration and start up/commissioning costs are reduced.

AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au

Emerson Process Management 03 9721 0200 www.emersonprocess.com

100Tx industrial unmanaged switches Antaira Technologies has introduced 100Tx Industrial Unmanaged Switches with IEEE 802.3at (PoE+) technologies, Fiber Optics (SC/ST), and power input options from 12~36VDC to 48~55VDC. The series comes with Network Broadcast Storm Protection, and Port Break Alarm solutions, and is available in standard operating temperature models in -10 to 70°C, and extended operating temperature models in -40 to 75°C. The LNX-0501 and LNX-0602 series models come with 4-port 10/100Tx Fast Ethernet and 1 or 2-port 100Fx Fiber (SC/ST type connectors) in Multi-mode (2 km) or Single-mode (30 km) options. These 2 series versions come with Dual Power Input that supports 12~48VDC, and a built-in relay for a Port-Break Alarm solution. The LNX-0501 and LNX-0602 series provide users more Ethernet connectivity with 100Tx and 100Fx Fiber for distance extension solutions. Also available are PSE LNP-0500, LNP-0501, LNP-0602, LNP-0800, and LNP-0802 series models with IEEE 802.3at (PoE+) technology in which each 10/100Tx Ethernet port provides a maximum 30W power output solution to support any PD (Powered-Device) in any standard 802.3af (PoE) or 802.3at (PoE+) design equipment.

Antaira Technologies info@antaira.com.tw www.antaira.com.tw 24 www.pacetoday.com.au MARCH 2014

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

Wear-free decentralised soft starter

Receptacle extension simplifies connections in CI D1 areas TURCK’s HL (Hazardous Location) receptacle extension provides users with a connectivity solution for Class I Division 1 (CI D1) locations without the need to install conduits and poured seals. The HL receptacle extension also eliminates the need for intrinsic safety barriers by providing fully encapsulated housings joined by a welded aluminium armored cable available in lengths up to 20m. The extension threads into the conduit entry of a device in a CI D1 hazardous location and extends the connector into a Class I Division 2 (CI D2) area where it can be easily mated with a minifast connector. Due to the use of MC-HL cable and the explosion blocking qualities of the housings, this product has been FM approved for use in CI D1 areas without the need for installing conduit and poured seals or intrinsic safety barriers. The encapsulated housings resist up to a 6000 psi pressure surge. The minifast connector is IP67 rated and the extension has temperature range of -40° C to 90°C.

NORD Drivesystems has released a motor-mounted starter with an extended performance range for the economic distributed implementation of soft start and reversing functions, for motors from 0.25 to 7.5 kW. The compact SK 135E integrates motor overload protection through PTC thermistor monitoring, mains and motor phase failure monitoring, I²t monitoring, and magnetising current monitoring. The electronic, wear-free switching technology replaces motor circuit breakers, reversing contactors, and brake rectifiers, thus rendering entire control cabinets unnecessary in large facilities. As PTC thermistor connection cables and brake control cables are not required, either, installation becomes generally more cost-effective, space-saving, and faster. When the drives are ordered complete and wired with gearbox, motor, and starter, any assembly effort is reduced to simply tightening the screws and establishing the electrical connection, which is optionally with plugs. The soft start function reduces mechanical stress, preventing shocks during start-up and braking. A voltage boost can be programmed for applications requiring high break-away torques.

NORD Drivesystems 03 9394 0500 www.nord.com.au

TURCK 1300 132 566 www.turck.com.au

Enhanced Data Station Plus

Non-intrusive flow measurement at extreme temperatures

The Red Lion enhanced ZR Series of the Data Station Plus is designed to act as the key connection point for industrial data collection and management. The ZR Series offers protocol conversion, data logging and remote machine access – all at processing speeds six times faster than previous versions. The ZR Series simplifies complex plant floor environments by allowing disparate devices to communicate seamlessly using a 10/100 Base-TX Ethernet port that supports up to ten protocols simultaneously. In addition, the Ethernet port and three built-in serial ports leverage more than 250 communication drivers to convert numerous protocols simultaneously and connect and collect data from virtually any PLC, drive or bar code scanner. A built-in data logger logs tags at user-programmable rates before automatically time/date stamping each tag. The information can then be stored in an open CSV file format, allowing easy access from virtually any application. The ZR Series can also synchronise log files with any FTP and/or Microsoft SQL server for further analysis. In addition, USB host capabilities allow thumb drives for programming and log file storage as well as other USB devices to be used. To extend production monitoring to remote personnel, the Red Lion ZR Series also provides text message and email alerts. The improved extra large XGA size built-in webserver enables global access to data logs and allows information to be monitored using a smartphone or Internet-connected PC.

FLEXIM’s patented WaveInjector clamp-on mounting fixture enables the non-intrusive ultrasonic flow measurement of liquids at extreme pipe wall temperatures ranging from as low as -190 °C up to 400 °C and beyond. Since the WaveInjector is a purely mechanical solution, it can also be used – in conjunction with FLEXIM’s ATEX, IEC and FM approved transducers and transmitters – within hazardous areas. Thus, the WaveInjector realises long-time temperature stable, reliable and accurate clamp-on ultrasonic flow measurements at extreme temperatures in combination with the well-known advantages of the clamp-on ultrasonic technology: No process stops for installation combined with a virtually maintenance free measurement. Typical applications areas where the WaveInjector is employed are found at LNG terminals, Refineries or even molten salt flows at Central Solar Power plants – where pipe wall temperatures easily reach up to 580°C. Moreover, as the pipe segment, where the WaveInjector is installed at, will be reinsulated after installation, there are no thermal energy losses.

Control Logic sales@control-logic.com.au www.control-logic.com.au

FLEXIM info@flexim.com www.flexim.com MARCH 2014 www.pacetoday.com.au 25

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CONNECTIONS

5

minutes with...

I had the idea of franchising a take-away restaurant selling cooked sausages

Wayne Kent, Honeywell Building Solutions How did you come to be in this industry?

I began my career with an apprenticeship as a refrigeration and air conditioning technician.

It wasn’t long after this that I started my own business providing commercial refrigeration and air conditioning services on the far south coast of NSW, which I ran for six years.

But it was at Honeywell that I moved from working in a technical capacity to team management and then business management roles. I celebrated 20 years with Honeywell in September last year.

What do you see are the biggest opportunities for our industry?

At present, we’re seeing a lot of major projects with heavy infrastructure spend, providing a great opportunity to deliver large, integrated solutions. Yet, at the same time we’ve also seen shrinkage in the marketplace, with two major builders dominating the construction landscape.

With less buyers, the importance of customer satisfaction in project delivery becomes increasingly significant. Deliver a project on time and within budget and

there is much greater chance of securing repeat business.

What’s the best business idea you have that you will never use?

There are a couple of ideas that I’ve had that I may or may never use, in very diverse fields. Years ago, I had the idea of franchising a take-away restaurant selling cooked sausages. I was certain it would be a hit, as who doesn’t like a good snag?

Perhaps a little closer to what I do now is my second idea, which I may still pursue in the future. I think there is a great opportunity in the online space for buyers to have more of a say in what they’re prepared to pay for goods – I can assure you it’s different to what is in the marketplace at present. I can’t say too much more, but stay tuned!

What’s the greatest challenge in your job?

In my role, I find it can be easy to get tied to a desk while focusing on overall business performance and growth. But I’ve always been committed to customer satisfaction

and I find no better way to do this than to be out in the field, engaging with customers at a senior level and maintaining those relationships to ensure we’re delivering the best results. So the challenge is in maintaining oversight across the business while having my finger on the pulse in terms of the customer experience.

If you could do anything else, what would it be and why?

I think that as I’ve gotten older, I’ve developed a stronger interest in not-forprofit work. For one, I’ve seen some of what Honeywell is doing on a global scale in terms of giving back to the community, with organisations like Habitat for Humanity.

I also participated in the CEO Sleepout this year and it was inspiring to see corporates getting involved in this initiative.

If I could do anything else, I would like to use my business experience to help drive the success of a not-for-profit.

[Wayne Kent is Regional General Manager – Pacific, Honeywell Building Solutions.] www.buildingsolutions.honeywell.com

INSTRUMENTATION

Instruments to surge ahead Increased functionality will bring enhanced performance and productivity, writes Jim Pinto.

THOUGH little has changed with instrumentation for several years, increased functionality will bring major productivity advances in the coming decade.

Advances include instant access to data, displays and intelligence anywhere on the network, improved network communications, intrinsic safety and more. Progress is impacted, in particular, by wireless technology, mobile devices and industrial Internet.

Most process sensors have not and will not change in the foreseeable future.

The most measured process variable is temperature, followed by pressure flow and many others. Thermocouples are 26 www.pacetoday.com.au MARCH 2014

the most common temperature sensors, with millivolt signals that need to be boosted in most practical applications.

Process instruments also encompass controls to operate actuators such as heaters, solenoids, valves, regulators, relays or circuit breakers.

For sending low-level signals without any degradation over any distance, sensors are typically connected to transmitters that produce output signals, usually in the form of a current signal, 4-20 mA. There are many other output options, including voltage and frequency, which are converted for use with networks such as Fieldbus and

Ethernet for display or control in PLCs, DCS or SCADA systems.

There’s an enormous installed base of 4-20 mA transmitters, some of which have been retrofitted for use with digital protocols such as HART, to connect with configuration, test, calibration, diagnostics devices and portable computers. Many users have yet to realise that HART technology’s greatest value comes from real-time asset management and control systems.

Today, one can connect a laptop or wireless mobile device to gain instant access to all the data, displays and intelligence that resides anywhere

on the network. This capability, in combination with the self-tuning, selfdiagnosing and optimising features of modern process control, makes startup activity and operational routines easier and more efficient.

Users demand better performance, more uptime and easier maintenance.

Smart instruments meet these demands.

The payoff is less complexity, better performance and reduced costs. The evolution of process instrumentation will accelerate when international standards have been established for networked communications.

Jim@Jimpinto.com

HURRY, TIME’S RUNNING OUT!!

Be quick and send your nominations in for the 11th annual PACE Zenith Awards. 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.

Categories • Manufacturing • Food & Beverage • Machine Builder • Mining & Minerals Processing • Oil & Gas • Power & Energy Management • Lifetime Achievement Award • Transport, Power & Infrastructure • Water & Wastewater • Young Achiever • Best Fieldbus Implementation • Project of the Year All finalists will be profiled in PACE Magazine and on the website. They will also be given two free tickets to the gala dinner where the winners will be announced.

For more information visit www.pacetoday.com.au/awards Proudly sponsored by

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Making things right Industry 4.0

Success of manufacturing in Australia? … let’s drink to that.

Making things right – The future of manufacturing is Industry 4.0 www.siemens.com.au/futureofmanufacturing

The world is entering the fourth industrial revolution – known as Industry 4.0.

Countries like Germany and the US are quickly starting to embrace and prepare for this industrial revolution and Australia needs to do the same or we‘ll be left behind.

There’s a difference between making things and making things right. Our technology is helping many of Australia’s food and beverage manufacturers make things right. Making things right, means making the right kind of progress. It means understanding that decisions today will affect tomorrow. That’s why Siemens is redefining manufacturing, making it more nimble, adaptable, intelligent; from design to prototype to production – in rapid innovation cycles.

So factories can perform faster, better and produce more with fewer resources.

Are you ready for a successful future of manufacturing for your business? Scan QR Code for more and a white paper on Industry 4.0 or contact Siemens: manufacturing.au@siemens.com Call 137 222 and ask about Industry 4.0

Answers for Industry.

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