www.pacetoday.com.au
PACE PROCESS & CONTROL ENGINEERING
Automatic orbital welding Technology gains favour in industries where leak integrity is paramount. Behind the Scenes 10
Mine’s top-down approach Software helps Iluka’s mine to be commissioned under time and budget. Mining Automation 15
Scheduling delivers benefits ZZZ QHWELWHU FRP DX MAY 2011
VOL.64 NO.4
INSIDE THIS ISSUE
Safety Systems 6
Lifecycle management To be effective, standards must specify safety lifecycle activities that need to be followed over the entire life of a production system. Special Report 19
Zenith Awards Finalists We reveal the best projects in eight categories as well as our outstanding youngsters and lifetime achievers. MasterClass 22
Load Tap Changer An innovative solution for cleaner supply and cost savings with phase angle firing. IICA News & Views 42
Australia left behind Instrumentation education cannot continue as a tack-on to other courses.
BY KEVIN GOMEZ LATE last year, global enterprise applications company, IFS purchased 360 Scheduling. The acquisition will strengthen IFS’ market position in mobile workforce management. 360 Scheduling, based in Nottingham in the UK and with sites in France and the US, is a provider of mobile workforce scheduling and optimisation software. The company offers 360 Scheduling, a scalable service-oriented architecture (SOA) optimisation framework which delivers advanced mobile workforce scheduling for both on-premises and cloud (software-as-a-service) deployment. Organisations with assets have their schedules of work; some of it cyclical including planned maintenance and improvements. The issue arises when an organisation has to handle planned cyclical work with the reactive work that may arise because of a breakdown. “A lot of our customers used to have two types of workforces – people who do project installation as well as an emergency team on standby,” said Laurent Othacéhé, CEO of 360 Scheduling. But things are drastically different with an integrated workforce, with team members cross-trained and given the work as it happens. Nottingham-based Othacéhé spoke to PACE when he was in Sydney recently, and offered some insights into the software. Take the example of a company starting maintenance work on a length of pipe work. The four-member team has to finish this three-day job in a one week window. If an emergency happens within 10 km, this team can halt work, and after
Laurent Othacéhé: Australia is an important market for mobile workforce systems. ensuring the site’s safety, move on to handle the emergency. “This company does not need to get staff from 100 km away when it can draw upon the services of a team doing nonemergency jobs just 10 minutes away,” Othacéhé explains. “Because of this ability, operational efficiency really goes through the roof. We’re able to merge very efficiently, the schedules and the rostering of staff.” When the team arrives on site, they will have delivered to their mobile terminal all the information on the bit of plant they’re going to service: the history of incidents, modifications, tools required. There are significant savings to be had with such a scheduling system but the client company must invest some of its intellectual bandwidth, explains
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Othacéhé. Once the system is in place it takes about six to nine months for a company to adapt its business processes. “Our customers will then be able to deliver 10 to 20 per cent more with the same workforce,” he explains. IFS intends to offer the 360 Scheduling product both as an integrated part of IFS Applications and as a standalone solution. Economies of scale and synergies will be realised by 360 Scheduling utilising IFS’ international infrastructure as well as having similar industry focuses. “This is something we’ve been crying out for, for a long time, so it’s exciting that we’ve finally got an excellent product that we can bring to market,” Rob Stummer, managing director of IFS in Australia told PACE. www.IFSWORLD.com
NEWS
EDITOR’S MESSAGE
PACE
Overkill in desal?
PROCESS & CONTROL ENGINEERING
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Next Issue Test & Measurement SCADA & MES ● Instrumentation ● Fluid Handling ● ●
THIS is always a special time of the year for PACE as our mailboxes are inundated with entries to the Zenith Awards. This year it hasn’t been a trickle; rather it’s been a flood of high-quality nominations. Sydney’s Doltone House will be abuzz on June 16 – get your tickets soon (02 9422 2890) and be a part of the celebration. We will commend the professionals behind some of the best projects in the region, encourage up and coming talent and also celebrate those who have devoted a significant part of their their lives to the industry. With this issue, PACE marks 58 years as the leading publication in the industry, having begun life as a journal for the chemical sector. The magazine was first published in May of 1953, under the title Chemical Industry and Engineering. The publication has evolved over the decades and today PACE is a multi-media entity and the hub for Australia’s process control and automation community. An interesting report by the Productivity Commission crossed our desks this week. Titled Australia’s Urban Water Sector, the voluminous tome believes the country has overinvested in desalination. The report estimates
the decision to invest in desalination as opposed to lower-cost alternatives will cost Melbourne and Perth consumers and community $3.1 to $4.2 billion over 20 years, depending on modelling assumptions. The report pointed to the possible risk that desalination plants may be built but not used, citing the example of Santa Barbara, California, which built a desalination plant during a 1991 drought. The drought ended before the plant was on-line, and the plant was mothballed after construction. Writing for The Conversation, Paul Willis, a research fellow at the Monash Sustainability Institute, Monash University, was critical of the report, which he contends prioritised economic factors over sustainability or conservation. He also pointed out that conservation of water used in showers is on par if not more important than trying to limit desalination from a sustainability point of view, since “the energy used to heat water in the average domestic hot water unit is about ten times the energy used to desalinate the same volume of water.” Kevin.Gomez@reedbusiness.com.au
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FROM
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3D print undermines economies of scale BY JIM PINTO THE industrial revolution of the late 18th century brought the mass production of goods and created economies of scale which changed the economy and society in ways that nobody could have imagined at the time. Now a new manufacturing technology is emerging which does the opposite. Three-dimensional printing makes it as cheap to create single items as it is to produce thousands and thus undermines economies of scale. It will have as profound an impact on the world as the factory did. Most of today’s manufacturing is subtractive – it trims chunks of mate-
rial to required shapes – cutting, grinding, shaving, trimming. Then the parts are assembled into final products. 3D printing is an additive manufacturing technology. A 3D printer works by using a computer to create a series of cross-section slices. Each slice is then printed one on top of the other to create the 3D object. The additive approach to manufacturing has many big advantages. It cuts costs by getting rid of production lines. It reduces waste enormously, requiring as little as one-tenth of the amount of material. It enables the production of a single item quickly and cheaply. Parts can be
created in shapes that cannot be achieved with conventional techniques, resulting in new, much more efficient designs. Parts and assemblies can be made of several materials with different mechanical and physical properties in a single build process. It’s as cheap to create single items as it is to produce thousands. It may have as profound an impact on the world as the factory did more than a century ago. 3D printing is already competitive with plastic injection-moulding for runs of up to 1,000 items, and this number will rise as the technology matures. Jim@JimPinto.com
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NEWS
MINING
Saline water brims with sustainable savings says CSIRO BY CLARISA COLLIS CSIRO research is finding currency in the green economy by capturing the potential of saline water for use in mining and mineral processing. CSIRO project leader Dr Hal Aral says the industry is facing more “desperate times” through a combination of expanding hydrometallurgical operations, declining ore grades, escalating production pressures and water scarcity. This is reflected in the “desperate measures” operators are using to secure their water requirements, specifically the use of saline water. This is the case both domestically and internationally. “Highly saline underground waters are often the only water available to miners in inland Australia,” Aral says. “And in northern Chile, seawater is pumped tens of kilometres to mine sites at higher altitudes.” Aral says in Australia the mining industry’s use of water increased about
29 per cent between 2000-01 and 200405, when it reached two per cent of the total national water consumption. But mining is competing with other water users such as agriculture for the scarce resource, and is also facing other challenges such as climatic conditions and regulatory requirements. Using saline water is seen as a practical response that will also improve the sustainability of mineral processing generally, and CSIRO’s Minerals Down Under Flagship has been investigating this area since 2008. CSIRO is examining the use of saline water in physical processes, such as crushing, grinding, flotation, magnetic and gravity separation, and as a diluting agent in lixiviant preparation. The research concentrates on using seawater and saline underground water without any pre-treatment, and recycling available water as much as possible. While saline water can cause corrosion
ACT NOW: CSIRO’s Hal Aral.
to pumps, pipes and other components at mine and mill sites, Dr Aral says the advantages outweigh the disadvantages where fresh water is unavailable. “Use of seawater, with little or no desalination, could enhance the economic feasibility of
mining operations.” In one case study, process flowsheets have indicated that a South Australian copper concentrateproducing company could reduce its reliance on bore water by recycling saline water from processing. The research estimated the company could reduce its bore water consumption by about 260t per hour, also effectively reducing power costs and associated greenhouse gas emissions. Aral says this translates into a saving of about $250,000 a year based on pumping 260t per hour from the borefield to the plant at a cost of 10 cents per kilowatt hour. The only modifications required would be some additional pumps. Potential savings would significantly stack up over the life of the mine. [Source: CSIRO’s Process magazine, February 2011] Hal.Aral@csiro.au / 03 9545 8823
Performance Measurements Are Within Your Control As industrial systems increase in complexity, optimizing your system with advanced measurements and control is critical. The open NI LabVIEW graphical development environment and NI CompactRIO hardware can help reduce costs with precision measurements, machine vision, motion control, and the ability to connect to existing automation equipment through industrial communication. PRODUCT PLATFORM NI LabVIEW NI CompactRIO NI Vision Products NI Motion Control Products NI Wireless Sensor Network
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©2011 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 01407
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Australia: 1800 300 800 New Zealand: 0800 553 322
NEWS
Mobility app for the iPad
ENHANCED: The Teamcenter Mobility app promises better responsiveness to customers by decreasing the time to respond to issues. SIEMENS PLM Software, has released its Teamcenter Mobility mobile device application for instantly accessing — from WiFi or mobile broadband-available locations – the product knowledge managed by its Teamcenter software. Through the use of this new app, which is being initially deployed on the Apple iPad, companies can enhance their ability to interact with product data and workflows at the right time, in the right place and in the right context to further enhance the speed and accuracy of decisions made throughout a product’s lifecycle. “Due to their accelerated worldwide adoption and their role as a company’s single source of all product and process knowledge, PLM systems have become a competitive necessity for the global manufacturing community,” said Joe Barkai, Practice Director, Product
Lifecycle Strategies, IDC Manufacturing Insights. “However, in order to effectively leverage this vast pool of information for fast and intelligent decision making, it needs to be made instantly available to all stakeholders in the product lifecycle process at the point of activity that decisions are made. Teamcenter Mobility helps make valuable product knowledge much more accessible to a significantly broader audience of users throughout the extended enterprise.” The app enables individuals to search, view and interact with product and process workflow information on the spot using a mobile device. Companies can react quickly to the changing environments associated with all product lifecycle disciplines from design, manufacturing and maintenance. www.plm.automation.siemens.com
Henkel wins award for hot melt BY KEVIN GOMEZ HENKEL Australia / New Zealand recently won a prestigious award for their problem solving investigation into Supra hot melt raw material at the AI Regional Technical meeting in Taiwan. “It is a significant achievement to have recognition at this regional event,” enthused Henkel Australia president Jeremy Hunter. The majority of the investigative work was conducted at Henkel’s Seven Hills (Sydney) laboratory supported by the NZ team. Supra is a water white,
superior heat stability hot melt based on a novel polymer technology which enables excellent adhesion to a wide range of materials. “The work was around developing the optimum heat stability,” Geri Moorman told PACE. Moorman is customer innovations manager, Adhesives Technologies, Henkel Australia. Supra is mainly used in the packaging industry to seal cartons on high speed packaging lines in the food and beverage industries.
“Now we are also level switching with non-contact microwave technology.”
New from VEGA: the microwave barrier VEGAMIP. Maintenance-free technology for level switching under rough conditions. Ideal for abrasive media or very high temperatures and reliable, even with buildup. www.vega.com/au/innovation Phone: 1800 817 135
www.henkel.com.au MAY 2011 www.pacetoday.com.au 5
OPINION
TOP TWEETS
Here’s what you may have missed this April if you weren’t following @pacetoday on Twitter:
VIEWPOINT
Resolving problems
❏ How to tackle system design challenges through early verification. http://dlvr.it/MqBZN
To be effective, standards must specify safety lifecycle activities that ❏ Dassault Systèmes to offer endto-end PLM following Intercim acquisition. http://dlvr.it/M6Gtv ❏ Regal Resources starts pilot for biogenic methane enhancement. http://dlvr.it/M5RBG ❏ Festo develops world's first robotic bird [VIDEO]. http://dlvr.it/LtnzL Follow @pacetoday on Twitter for the latest news, analysis, new product information and commentary. And never miss out again.
A
CCIDENTS continue to occur in many manufacturing facilities, even those where safety systems and other safety protection has been installed. Studies confirm that these failures are due largely to inadequate safety management. IEC 61511 specifies 12 steps in the safety lifecycle. These are segmented into four phases: analysis, realisation, maintenance, ongoing functions. Safety Lifecycle I: Analysis Phase. The analysis phase includes the initial planning, identification, and specification of safety functions required for the safe operation of a manufacturing process, including documentation of the safety requirements. Specific activities include:
Perform Hazard and Risk Analysis: Determine hazards and hazardous events, the sequence of events leading to hazardous condition, the associated process risks, the requirements of risk reduction, and the safety functions required. Allocate Safety Functions to Protection Layers: Check the available layers of protection. Allocate safety functions to protection layers and safety systems. Specify Requirements for Safety System: If tolerable risk is still out of limit, then specify the requirements for each safety system and their safety integrity levels. Safety Lifecycle II: Realisation Phase. The realisation phase includes not only design, installation, and testing of safety
systems, but also the design, development, and installation of other effective risk reduction methods, such as mechanical trips and barriers. Activities include: Design and Engineer Safety System: Design system to meet the safety requirements. Design and Develop Other Means of Risk Reduction: Means of protection other than programmable safety systems include mechanical systems, process control systems, and manual systems. Install Commission and Validate the Safety Protections: Install and validate that the safety system meets the all safety requirements to the required safety integrity levels Safety Lifecycle III: Maintenance Phase.
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in safety lifecycle management need to be followed over the entire life of a production system, writes Dave Woll. The maintenance phase begins at the start-up of a process and continues until the safety system is decommissioned or redeployed. Specific activities include: Operate and Maintain: Ensure that safety system functions are maintained during operation and maintenance. Modify and Update: Make corrections, enhancements, and adaptations to the safety system to ensure that the safety requirements are maintained. Decommissioning: Conduct review and obtain required authorisation before decommissioning a safety system. Ensure that the required safety functions remain operational during decommissioning. Safety Lifecycle IV: Ongoing Functions. Examples include managing functional
All major safety standards have specified similar safety lifecycles differing only in the details. safety, planning and structuring the safety lifecycle, and performing periodic safety system verification and safety audits over the whole lifecycle. Specific activities include: Manage Functional Safety, Safety Assessment, and Safety Audit: Identify the management activities required to ensure the functional safety objectives are met.
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Plan and Structure Safety Lifecycle: Define safety lifecycle in terms of inputs, outputs, and verification activities. Verify Safety System: Demonstrate by review, analysis, and/or testing that the required outputs satisfy the defined requirements for each phase of the safety lifecycle. Activities for Phases I to III are normally carried out consecutively, while Phase IV runs concurrently with the other phases. Like all models, the safety lifecycle is an approximation and there are significant iterations between phases. The standards define requirements for safety management, rather than just system development. Not all safety lifecycle phases will be relevant to every
application. Management must define which requirements are applicable in each case. The standards do not prescribe exactly what should be done in any particular case, but guide management towards decisions and offers advice. Management continues to be responsible for taking and justifying appropriate actions. Users should realise that safety systems by themselves do not achieve safety. People working within a strong safety culture achieve greater safety. It is management’s responsibility to foster and maintain such a culture. [Dave Woll (dwoll@arcweb.com) is Vice President, ARC Advisory Group.] www.arcweb.com
Introducing a smarter way to calibrate temperature Beamex introduces a smarter, more efficient and accurate solution for calibrating temperature. Beamex® has two different dry block series: the Beamex® FB Series Field Temperature Blocks and the Beamex® MB Series Temperature Metrology Blocks. The dry blocks in the FB Series are lightweight, high-accuracy temperature dry blocks for industrial field use. The dry blocks in the MB Series deliver bath-level accuracy for industrial applications. Portable calibrators Workstations Calibration software Professional services Industry solutions
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MAY 2011 www.pacetoday.com.au 7
NEW PRODUCTS
Metal shielded Profibus DP connectors
10,000 psi Mini Valve
Displacement sensor
Weidmuller have expanded their range of Profibus connectivity products with the release of Shielded Metal Profibus DP Connectors. Perfect for industrial use and ideal in water, wastewater and general factory automation environments, the broad range of Weidmuller Profibus DP Connectors are completely encased in metal shielding. The outer metal shielding works to eliminate electrical noise. The secure and reliable communications point of the connectors helps to reduce wiring errors on installations. Designed as compact units, the Weidmuller metal Profibus DP Connectors can be used in small, tight areas with ease for convenience. Available in numerous models including 35º and 90º angled cable entries with tension clamp connection, and 90º with M12 plug entries. Plugs come with a terminating switch and programming plug options.
NOSHOK 100 & 150 Series Mini Valves are available in zinc nickel plated steel, electro-polished stainless steel and 360 brass. The valves are equipped with both a Viton O-Ring seal and a Teflon back-up ring below the stem threads to protect them from corrosion and galling. The stem threads are rolled for strength and ease of operation. The patented design incorporates an improved internal body-to-bonnet, metal-to-metal seal.
Designed for very short measuring ranges between 50 and 200 mm, Turck developed the first miniature linear displacement sensor, LI-Q17, uniting all the positive qualities of customary measuring systems in one solution without having the disadvantages. The LI-Q17 doesn’t work with a magnetic locator but with the resonant circuit measuring principle, where an object’s position is detected via an inductive oscillating system.
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CF12 Series Thermal Flow Switch The intelligent Sitron CF Series of Thermal Flow switches from Control Components is ideally suited for flow and low flow detection of liquids or gases in pipes or ducts. With no moving parts to wear out, the inexpensive CF Series will deliver a longer life and lower maintenance costs when compared with alternative mechanical switches. The combined flow switch and transmitter is extremely durable and performs reliably under general industrial applications and
LabSizer for large-volume particle sizing The Insitec LabSizer provides robust, large-volume dry powder particle size measurements (0.1 to 1000Îźm) in manual and automated plant laboratories. Suitable for the analysis of samples up to 150g, it offers fullyautomated SOP-driven operation. Maintenance requirements are low, and simplified by the modular design of the instrument, a feature that also facilitates integration within an automated lab. The laser diffraction tech-
nology at the heart of every Insitec system is now the standard in most particulate processing industries and has been pioneered and developed by Malvern for more than 30 years. All Malvern Insitec systems are designed for industrial use. Their rugged construction and robust technology reflect the exacting demands placed on analytical instrumentation. ATA Scientific 02 9541 3500 / www.atascientific.com.au
harsh process environments with average response times of between 1 to 10 seconds. The display chain of 8 LEDs helps the set point adjustment. All models are manufactured using 316 stainless steel and can be coated with Halar when necessary for particularly aggressive mediums. Standard operating temperatures for the CF 12 Series are between -10 to +120°C. Control Components / 02 9542 8977 www.controlcomponents.com.au
Transmitters for HVAC To ensure accurate and stable measurement data, Vaisala introduces two new humidity and temperature transmitters, designed for use in cleanrooms and demanding HVAC applications specifically. The Vaisala HUMICAP Humidity and Temperature Transmitters HMT120 and HMT130 complement Vaisala’s existing offering of relative humidity measurement instruments that covers all applications from ventilation to process control. Designed for indoor and outdoor use, the transmitters can be either wallmounted or used with a remote probe for installations inside air handling units and difficult to reach places. Vaisala 03 9815 6700 / www.vaisala.com/hmt120
MAY 2011 www.pacetoday.com.au 9
BEHIND THE SCENES
Automatic orbital welding systems Automatic orbital Gas Tungsten Arc Welding has gained favour in a variety of industries in which maximum leak integrity or high performance are of paramount importance, writes John Glessman.
F
INDING skilled welders is becoming difficult and will only become more difficult in the near future. According to the Welding Technology Institute of Australia, “the need for professionally qualified welding personnel has been widely recognised on a global basis.” One means of addressing the shortage is through automated systems, which produce more work with fewer people. Since its introduction to the aerospace industry in the 1960s, automatic orbital Gas Tungsten Arc Welding (GTAW) has gained favour in a variety of industries in which maximum leak integrity, high performance, or ultra-cleanliness are of paramount importance.
Automatic orbital welding provides enhanced precision and reliability compared to manual techniques. Small, portable inverter power supplies, advanced control systems and other advancements have made orbital welding systems practical for a range of applications. The advent of new technology has led to further improvements in these systems. Power supplies designed with open platforms provide welders of various skill levels with even more welding options and an ease of use not previously available. Enhanced programs and controls help improve the consistency and reliability of welds as well as operator efficiencies. This article will review several of these advancements.
Orbital welding power supplies have been incorporating more skills of the welder into the welding system itself, enabling efficiencies in automation, programming, and documentation. To achieve these efficiencies, a power supply must be designed with an open platform that allows an interface with standard devices and the ability to expand as technology evolves. The result is a welding system that meets the expanding needs of various industries. Automation. Aspects of the welding process that historically would be undertaken manually, such as travel speed, arc gap, current control, and gas flow are controlled through electronic and > mechanical means. This minimises
BENEFITS
VALUE OF ORBITAL WELDING Orbital welding is used in applications ranging from biopharmaceutical to refining operations. Orbital welding is finding increasing value because it can deliver highly repeatable, consistent and quality welds easier than ever before. Advanced technology is making orbital welding a cost-effective and viable option for plant managers, weld operators and others who have involvement in the welding process. The result is the ability to complete more welds per day.
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BEHIND THE SCENES
Innovative valve automation
ENHANCED: Maintaining proper shielding gas control at the weld head is critical to protecting the weld from atmospheric contamination. Newer orbital welder designs feature automatic shield gas control in the weld head.
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many of the variables in the welding process that can lead to errors or defects and enables welders to focus most of their attention on overseeing the process and completing actual welds. Programming. Every orbital weld – regardless of the application – requires the creation of a program, which controls the output characteristics of the system. User-friendly systems simplify programming by providing step-by-step procedures to create programs for a variety of tube diameters, wall thicknesses and base materials. Rather than build programs manually using charts or tables, assessing past weld parameter data, or relying on memory, the operator can create a program by selecting pertinent data from “pick lists” or dropdown menus. The system then creates the initial program for the operation, which can significantly reduce the chance for human error and reduce start-up time. This is also very helpful when welding materials that are unfamiliar to the user. If additional assistance is needed, a quality orbital welder supplier will also offer assistance in developing welding programs. Newer orbital welding systems offer numerous preset programs and enhanced user interfaces for programming ease. Models are available with integral USB ports that enable operators to plug in a keyboard, mouse, and/or a number keypad for easier data entry. Operators may also download welding programs via a USB flash drive or update operating system software to add features or functionality. Durable, integrated colour touchscreens also help with programming ease. Documentation. Traditionally, the documentation process is costly and time consuming. Today’s orbital welding technology enables data to be stored within
the system for retrieval and transfer to databases for analysis and reporting. High-speed thermal printers built into newer orbital welders also help with documentation.
Weld repeatability The automated orbital welding process aids in achieving weld repeatability and consistency over extended periods of time. With manual welding human fatigue can become a factor. Although the operator may be highly skilled and experienced, he may produce inconsistent results because he literally is completing each weld by hand. With orbital welding, the electrode is accurately rotated in an orbit around a joint on a rotor. The rotor and electrode are housed in the weld head, which rotates around the tube. The process is highly controlled, ensuring high-quality welds that can be produced on a consistent and repeatable basis. Orbital welding systems perform a set of operations in a controlled manner where variables are maintained at preset levels. The system automatically starts and completes the weld, stepping from one variable setting to the next at a specific location along the joint or at a predetermined time during the process. Gas Control. Automated orbital welding generally uses the GTAW process, which operates by establishing an arc between a nonconsumable tungsten electrode and the base material that is being welded, creating a weld puddle. The electrode is positioned in the weld head. The electrode and weld puddle are both surrounded by a shielding gas, which is fed through the weld head to protect the electrode, molten weld puddle, and solidifying weld metal from atmospheric contamination. The heat
produced by the arc melts the base material. The electrode moves along the joint and progressively melts and joins the adjoining surfaces. Newer orbital power supply designs feature automatic shield gas control to the weld head. Systems with automatic shield gas control eliminate this inefficiency or the possibility of negatively affecting the weld quality due to an incorrect setting. Blast Purge. Further gas control advancements enable operators to improve their efficiency when welding at locations where long distances exist between the power supply and weld head. A sufficient gas volume must be present at the weld location before starting a weld. Newer welding systems utilise a blast purge feature to rapidly fill the lines and then automatically return gas flow to normal levels, allowing operators to start a weld sooner.
Power considerations When choosing an orbital welding power supply, operators should look for systems that enable them to perform
When choosing an orbital welding power supply operators should look for systems that enable them to perform welds for a wide range of applications. welds for a wide range of applications. They should also look for systems that limit electrical interference. Higher Amp Outputs. Power supplies with higher power outputs are capable of welding larger diameter and heavier walled tubing and/or piping while maintaining consistent welds. Newer welding systems offer the power output needed to weld the heavier walled components found in general industrial applications like oil and gas while still having the ability to weld smaller diameter thin walled tubing for R&D or semiconductor applications.
Electromagnetic Interference. Initialising the welding process requires a high-frequency, high-voltage arc start, which could result in electromagnetic interference (EMI). Frequent EMI resulting from a welding project could prove to be a nuisance or worse in the case of computers shutting down and causing work to be lost. Technology in arc starting has improved, and welding systems with low EMI arc start technology allow the arc start to occur without affecting the operation of equipment in close proximity. Small, lightweight orbital welding systems are a practical option. Remote controls and detachable weld heads and fixtures allow joints to be pre-positioned and enable orbital welding to be conducted in hard-to-reach places. [John Glessman (john.glessman @swagelok.com) is manager, welding system products, for Swagelok Company.] Swagelok 08 8369 0899 www.swagelok.com
STANDARD: With orbital welding, an electrode housed in the weld head rotates around the tube. The process is highly controlled, ensuring highquality welds that can be produced on a consistent and repeatable basis.
Advan-Touch: Out Of The Box, Install And Connect! Wonderware and Advantech are combining their leading products InTouch visualization and Windows XP Touch Panel Computers to provide the most cost effective SCADA/HMI TPC offering. This unique offering delivers pre-installed Operator Interface units that benefit users as follows: • • • • • •
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MAY 2011 www.pacetoday.com.au 13
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BEHIND THE SCENES
Mine benefits from top-down approach A unique approach and a special software package enabled Iluka’s Jacinth-Ambrosia mine to be commissioned under time and budget, writes Cedric Brown.
J
ACINTH-Ambrosia represents Iluka’s first project in the Eucla Basin, where it holds exploration tenements of approximately 50,000 sq km. The deposit is 270 km from the coastal centre of Ceduna. Mineral sands were first discovered in 2004 and the Iluka board approved development in May 2008 with construction beginning in July 2008. The decision followed extensive exploration delineation work and feasibility studies. Project completion and commissioning activities were achieved in November 2009. The project was completed under time, under budget and delivered without lost time injury. During the initial years of production, Jacinth-Ambrosia mine will produce approximately 300,000 tonnes of Zircon, 45,000 tonnes of rutile and 170,000 tonnes of ilmenite per annum.
Mining processes Combined resources at the deposit comprised more than 9 mt of heavy mineral sands with more than 4 mt of Zircon and it has a current mine life of 10 years. The onsite village includes accommodation for 160 people, complete with recreational facilities – pool, tennis and basketball courts and an unsealed airstrip.
SOFTWARE: A factor in the success of the Jacinth-Ambrosia project was LE80JV’s experience in the automated production of electrical drawings. Mining and processing at JacinthAmbrosia utilises a combination of new, fit-for-purpose equipment, as well as existing assets. The latter included a wet concentrator plant relocated from the company’s US operations. The dozer-trap mining method is employed at the open-pit operation. Ore is processed into heavy mineral concentrate (HMC) at the on-site wet concentrator plant and then trucked 270 km to Port Thevenard, approximately 3 km
south of Ceduna. The ore is then shipped to the Port of Geraldton and transferred to Iluka’s processing plant at Narngulu, about 15 km from Geraldton, which was expanded as part of the development of Jacinth-Ambrosia.
HIGHLIGHTS ●
Dozer-trap mining method is employed at the open-pit operation
●
LE80JV is a 50/50 joint venture between LogiCamms and Electro80
●
JV focused on implementing large scale control systems projects in the resource sector
●
Used top down methodology that emphasised formal documentation of system functionality
●
Promis*e software helped the team meet tight project deadlines
Economic benefits Jacinth-Ambrosia produces a premiumgrade Zircon displaying opacifier qualities, making it suitable for ceramic applications. The rutile and ilmenite >
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MAY 2011 www.pacetoday.com.au 15
BEHIND THE SCENES
product streams will be marketed for welding and other titaniumbased applications. The project could be divided into services (with 84 per cent spent in South Australia and 16 per cent other) and materials (with 60 per cent spent in South Australia and 40 per cent other). The main boost to local businesses and employment through its expenditure occurred during the project’s development phase in 2008-2009. During the construction phase of the project, local contractors were selected from Eyre Peninsula to carry out works such as electrical, plumbing, steel fabrication and earthmoving. Iluka partnered with LE80JV for the electrical and automation portion. A joint venture was formed in 2004 between LogiCamms and Electro80 to focus on large electrical and control systems projects in the resource sector. LE80JV is a 50/50 joint venture between two of Australia’s largest, most experienced vendor independent system integrators, the ASX-listed LogiCamms
and Electro80, a Division of Automation Partners. The venture has over three hundred professional engineers and 100 years of combined corporate experience. Since its inception, the LE80JV has completed a number of major projects and has supplied approximately $50 million of professional services and equipment including several hundred thousand hours of professional engineering services. Formed specifically to focus on the implementation of large scale control systems projects in the resource sector, the joint venture provides a compelling service offer. It also satisfies the joint venture partners’ aim of undertaking large projects whilst continuing to supply a high level of service to their respective existing client base.
Engineering services The strength of the LogiCamms Electro80 Joint Venture (LE80JV) comes from its capacity to work closely with its clients providing engineering
Top down methodology recognises that whilst quality implementation is important, identification and proper interpretation of process requirements is paramount. services throughout the entire development and the execution phase of large projects. This support is actively continued through the operational lifespan of the plant. The LE80JV was the EPCM provider of electrical, instrumentation, control and communications systems to Iluka Resources at its Jacinth-Ambrosia project. LE80JV was involved in all stages of the project, from the definitive feasibility study through engineering design, procurement, site construction, commissioning and production ramp up.
LE80JV use a top down methodology which emphasises the formal documentation of system functionality, including test cases and test records, prior to detailed design. This methodology recognises that whilst quality implementation is important, identification and proper interpretation of process requirements is paramount. A key factor in the success of the Jacinth-Ambrosia project was LE80JV’s experience in the automated production of electrical drawings using the Promis*e software package. The use of this tool and others assisted the engineering team to meet the tight project deadlines. Additionally the system simulation, rigorous internal software testing, validation and customer integration testing reduced the system commissioning phase on site. [Cedric Brown is General Manager, LE80JV.] LogiCamms Electro 80 Joint Venture www.le80jv.com.au 08 6253 2777
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7IRXMIRX´W VEHMGEP RI[ ZMWYEPMWEXMSR WSJX[EVI KMZIW ]SY XLI EFMPMX] XS WII ERH QEREKI ]SYV STIVEXMSR MR VIEP XMQI YWMRK ( 1:< SVKERMWIW ERH HMWTPE]W HEXE MR E ZMVXYEP [SVPH WS ]SY GER QEOI HIGMWMSRW WSPZI TVSFPIQW XYVR QEGLMRIV] SR ERH SJJ VYR MRHYGXMSRW ERH WEJIX] FVMI½RKW ERH PSGEXI TISTPI ERH IUYMTQIRX JVSQ ER][LIVI MR XLI [SVPH 8LIVI´W RS FIXXIV [E] XS QEREKI HEXE VMGL VIQSXI IRZMVSRQIRXW *SV QSVI MRJSVQEXMSR KS XS [[[ WIRGSQ GSQ EY SV GEPP
16 www.pacetoday.com.au MAY 2011
Survival of the Fittest
From rudimentary beginnings, machine vision systems
have developed into “smart cameras”, integrated self contained stand alone units with built in image sensors, communication interfaces, and industry standard outputs for connection to PLCs where image processing takes place. As well as possessing image capture capability, they are able to extract information from captured images and make decisions that are used in wider machine automation systems. However, most smart cameras remain expensive and require extensive integration by developers to be effective. Custom programs often need to be developed or off the shelf software from third parties must be adapted. This is why Sick has developed cost effective and user friendly 2D vision systems – compact, practical, and with reliable 2D imaging, integrated lighting, image evaluation and Ethernet interfacing. They are designed for trouble-free and fast solving of a diverse range of part inspection applications, are capable of inspecting parts in any orientation and position and have a predictable response time, making them ideal for packaging and small part assembly.
Evolution. Today’s leading Vision ‘smart camera’ systems by SICK
Sick’s Inspector vision sensors are perfectly suited to many machine vision applications. With increased performance and advanced features, the Inspector I40 in particular can perform part inspection tasks just like a smart camera. • • •
•
• • Early vision systems
PLC control over Ethernet for reading detailed results and control of set-up. Storage of images to FTP, an extension to the image log giving unrestricted memory capacity for complete production control. High resolution VGA imaging (640x480 pixels), providing high image quality and enabling inspection at higher accuracy or on wider areas without compromising speed. Powerful inspection tool sets for straightforward, easy-to-configure problem solving abilities, enabling easy solutions for tough target solutions. Emulator tools for fine tuning and testing of solutions. Flexible housing design with easy lens exchange, built-in illumination in red, green, blue or diffused white – without any extra wiring - illumination has never been easier!
Accelerate your business with Eurotherm the leader in industrial automation products Eurotherm specialises in improving the performance and efficiency of your plant operations both in regulated and nonregulated industries. Whatever your needs we can meet your requirements â&#x20AC;&#x201C; from a flexible, world class product to integrate into your system or a fully engineered system.
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PACE ZENITH AWARDS 2011 FINALISTS
And the finalists are… FINALISTS
C
ONGRATULATIONS to all finalists in the expanded edition of the 8th Annual PACE Zenith Awards program – PACE magazine’s process control, instrumentation and automation industry awards program for Australia and New Zealand. The following pages showcase pioneering process control, instrumentation and automation engineering projects across eight industries: Automotive & Manufacturing; Food & Beverage; Metal Products Manufacturing; Mining, Minerals & Exploration; Oil, Gas & Hydrocarbons; Power & Energy Management; Transport, Power & Infrastructure; and Water & Wastewater. The coveted Project of the Year Award will be selected from among these eight categories. This year, for the first time, we also turn the spotlight on the talented people behind our dynamic industry and have added two new categories: Young Achiever and Lifetime Achievement. The PACE Zenith Awards program was developed in 2004 as a simple breakfast event to publicly celebrate and recognise technological excellence and foresight in process control engineering projects in eight core
DRUMROLL: Record numbers expected at the 8th Annual PACE Zenith Awards event in Sydney. industries across Australia. The Zenith Awards have since extended its reach to projects performed in New Zealand, and by New Zealand companies. The Zenith Awards ceremony will take place on
Thursday 16 June at Doltone House in Sydney. Contact Alex Evans (02 9422 2890 or alex.evans@reedbusiness.com.au) to purchase tickets to the dinner. The evening is a great way to meet new customers and suppliers, network with industry representatives, or thank your customers for their support over the years. We are expecting a record number of attendees at this year’s awards ceremony, to reflect the strength of our process control and automation industry over the past 24 months. There will be a host of excellent projects battling it out for the top spot. Please join the staff at PACE in thanking our generous sponsors, without whom the PACE Zenith Awards would not be a reality. This year’s sponsors are AMS, Endress+Hauser, ABB, ifm efector, NHP, Schneider Electric, Siemens, Rockwell Automation. Check www.pacetoday.com.au regularly as we upload detailed information on the entries. Keep an eye out for the June 2011 issue of PACE, which will showcase the finalists that came in late. Good luck to all! 8th Annual PACE Zenith Awards www.pacetoday.com.au/awards
Four times the diagnostic power NEW Fluke 190 Series II ScopeMeter err®: The first four-channel scopes built for CAT IV environments. Four independent isolated input channels for testing esting of three-phase power electronics or three-axis testing industrial automation systems CAT III 1000 V/CAT IV 600 V safety rating ee more Fast sample rate and deep memory let you see and fix more h easy Up to 7-hour Li-ion batteries are standard with access battery door Learn more at
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SIMATIC S7-1200 Itâ&#x20AC;&#x2122;s the interplay that makes the difference
SIMATIC Controller The high-performance SIMATIC S7-1200 modular compact controller is the perfect fit for a full range of applications and is the latest addition to our complete and comprehensive automation solutions offering portfolio. You will experience an unprecedented level of efficiency for solving simple but highly precise automation tasks with a seamless range of SIMATIC HMI Basic panels and the powerful features of the innovative highly integrated SIMATIC STEP 7 Basic engineering system. To learn more about Siemens products in our eight solution areas of water, energy, environment, healthcare, productivity, mobility, safety and security visit www.siemens.com.au For further information, please call 131 773.
Innovation for generations.
PACE ZENITH AWARDS 2011 FINALISTS
Food & Beverage FINALISTS
Neo Vista Integra Systems and CSIRO
Frucor and CST Wastewater Solutions
PlantScan Black Mountain, Australian Capital Territory The high resolution Plant Phenomics Centre located at CSIRO Plant industry in Canberra, in association with Neo Vista System Integrators in Sydney, have developed a next generation phenotyping platform called PlantScan. It is designed to capture information on plant structure and function on an industrial scale, enabling the discovery of new traits and the selection of varieties for tomorrow’s agriculture. The system is composed of double conveyor belt, manually loaded, with plants held in position on pot carriers. Individual plants are identified by bar code; it is a first transfer station that diverts the plant to a split conveyor belt, which accurately positions the plant for imaging using laser proximity sensors. A rotating motor is then fitted with an incremental encoder with up to 65,536 lines per revolution and mounted on a scissor-lift platform, which ensures the plant is scanned from every angle.
Vertical Screws for Frucor Beverages Plant Manukau, New Zealand A compact vertical screen has been installed by Frucor to remove the solid debris from factory wastewater before its discharge into the sewer. The company chose the vertical screen from CST Wastewater Solutions as an ideal solution for the factory where the space was confined and there wasn’t room for bulkier equipment. It provides the company with an automated process that requires far less labour than the previous ‘flat’ screen method, which necessitated regular removal of the screens by forklift, followed by hand cleaning. The screen is positioned between the below-ground sedimentary sump and the main sump, which both hold wastewater from the enter plant at the Manukau City site. After the screen has removed solid material from the wastewater, its pH corrected and discharged into the sewer. The solids are mainly fruit pulp, but also include extraneous debris such as plastic bottle caps and hairnets. This material is discharged into a bin for disposal. The biggest benefit for Frucor is in terms of labour saved. Vertical screens are more or less automatic and maintenance free, making them very cost-effective. The function is controlled by the wastewater level, so that the screw switches on when the water rises.
Tooheys & Profibus International Competence Centre Tooheys Can Line Lidcombe, New South Wales Toohey’s turned to Tyco Flow Control, Australia’s first accredited Profibus International Competence (PICC) after realising its production line was suffering difficulties. Despite the company’s extensive Profibus experience, one of can lines encountered a host of problems which needed outside intervention. PICC engineers deployed the powerful ProfiTrace analysis tool and defined three problem areas; incorrect run lengths, wrong segmentation and poor terminations. The first step was to fix the two repeaters and the ProfiHub so it didn’t exceed the specified lengths. Once these issues were fixed, the can line stepped into gear. Profibus was also able to decentralise the safety system using ProfiSafe which was integrated and configured very easily. ProfiSafe allows the Tooheys team to pick up emergency spikes up to category 4 level.
Bluetongue Brewery and CST Wastewater Solutions Recycled Water Treatment/Green Energy Plant for Bluetongue Brewery Warnervale, New South Wales Pacific Beverages’ new Bluetongue Brewery features a water recovery plant, which targets best-practice water reuse standards. The plant also provides renewable energy for the brewery.. The system was installed by a partnership of CST Wastewater Solutions and Global Water Engineering (GWE). The wastewater passes through several pre-treatment steps before entering a GWE ANUBIX-B anaerobic methane reactor in which the wastewater’s organic content (COD) is digested by bacteria in a closed reactor, degrading the compounds and converting them into biogas and cleaned effluent. Biogas from the process is collected and reused as renewable energy to power the brewery’s boiler. Treated effluent continues to an aerobic post-treatment stage in which organic content is further reduced by GWE’s Membrox Membrane Biological Reactor. MAY 2011 www.pacetoday.com.au 21
MASTERCLASS
How to save costs with Load Tap Changer Mikaël Le Guern offers a solution for cleaner supply and cost savings with phase angle firing.
I/P SCR2 V2
SCR1 V1 Load
Example 1 I/P
SCR1 V1 V
Load
SCR2 V2
Example 2
Example 1 shows 2 taps on the secondary side of the transformer. EPower can actually have from 1 leg up to 4 single phase legs on the same unit. On Example 2, instead of having one traditional SCR with one leg, we have here one EPower unit with 2 legs controlling each one tap on the primary side of the transformer from one single input signal.
E
UROTHERM introduces an innovative function to maximise the power factor even when phase angle is the only alternative due for example to the nature of the load. Not only such solution can improve the power factor but as a matter of facts will reduce the harmonic generation, the Total Harmonic Distortion (THD) and will lead to substantial savings on energy cost. We already know that phase angle creates all sort of disturbances. This is an overview of various issues it can bring: • Decrease Power Factor which translates into reactive power consumption and higher cost for electricity. • Generation of harmonics • Higher CO2 emissions as utilities need to produce extra wasted energy (reactive power). • Increase of line power losses due to the higher current. • Transformers overheating as current harmonics increase iron and hysteresis losses. • Extra investment on corrective capacitors is often required. • These capacitors can eventually resonate with the line inductance. This could induce destruction of protection circuit. • Voltage Harmonics can create oscillatory torque in motors or other rotating machines directly connected on the mains. This accelerates the ageing of the equipment. Load Voltage V
Load Voltage V 700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700 8.33
16.67
25.00
33.33
0.00
Load Voltage V 700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700
700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700
8.33
16.67
Time (ms)
25.00
0.00
33.33
8.33
16.67
25.00
33.33
0.00
Pow er Factor 1.00
1.00
0.90
0.90
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0.90
1.00
0.80
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0.10 0.00 0.00
With LTC
0.40
0.60
0.80
Pow er (%)
1.00
0.00 0.00
Without LTC
0.20
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0.60
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Pow er (%)
At 20% power, it shows a drastic amelioration of the power factor which rises from a poor 45% to an excellent 89%.
22 www.pacetoday.com.au MAY 2011
1.00
0.00 0.00
0.50
0.10
0.10
0.10 0.20
33.33
Pow er Factor
0.80
0.45
25.00
1.00
0.70
0.89
16.67 Time (ms)
Pow er Factor
1.00
0.80
8.33
Time (ms)
Time (ms)
Pow er Factor
results on the power factor using an example with two taps (240Vac and 480Vac) versus a traditional solution in phase angle without LTC at 480Vac. For both we have: Vrms Load = 215V and Power = 20% of maximum nominal power. It’s important to wisely choose the value of the first tap in order to get the best result. As a matter of fact on most furnace when at temperature, the power demand will fall to around 20% to maximum 50%. The idea is to match this value with the maximum output power when at full conduction on the first tap. If calculated accordingly, the power factor will eventually be equal or close to 1 when the furnace is maintaining temperature during the process. Obviously, all this will have a serious financial aspect linked to the cost of energy. The following simulation represents a 600 kW furnace made of 6 equivalent single phase zones. The furnace runs at an average 30% power. For such furnace, it will thus be much more suitable to have a first tap at 277Vac (instead of 240Vac) which when at full conduction gives 33% power. This dramatic example, for the define conditions, shows a potential savings up to $44K+ on cost of energy using EPower with LTC features. The return on investment (linked to the limited extra cost for the tap trans-
Load Voltage V
700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700
0.00
• Acoustic noise in fluorescent tube ballasts. • Interference with telecommunication systems. • Image disruption on television set. The idea behind the Load tap Changer feature on EPower is to minimise all these inconveniences and especially to increase the power factor for economic reason but also to get a cleaner power supply without the disturbances. The Load Tap Changer is an arrangement of several channels of the EPower which allow controlling a transformer with several taps. The goal is to reduce dramatically the amount of harmonics rejected on the mains and to increase the Power Factor. One solution is to commute live a tap transformer. The EPower load tap changer will automatically switch from one tap to the next one based on the unique input signal and the internal feedback control in order to always tend to have load voltage as close as possible from a sinus waveform. Important: Taps can be either on the primary or on the secondary side of the transformer. The LTC propose two types of control: Primary or Secondary of the transformer. In both cases, each tap is controlled by one leg of the EPower SCR power controller. The selection of the used tap is automatic and self adjusting. Figures A, B and C illustrate the
0.20
0.40
0.60 Pow er (%)
0.80
1.00
0.00 0.00
0.20
0.40
0.60
0.80
1.00
Pow er (%)
At 25% power (Vrms load = 240Vac), while the power factor = 1 with the LTC, the traditional solution display a still poor value at 0.5.
PRESENTED BY
Furnace 600 kW
formers and cables) is a matter of months not years. To even more minimise the effect of phase angle and especially harmonic generation, it is even possible to combine both phase angle and zero cross firing with the Load tap changer functionality. For loads with heavy inrush current that require current limiting till it heat up, Phase angle can first be use on the first tap till it reach full conduction. Next instead of continuing in phase angle on the following tap(s), it is then possible to switch to fast zero cross firing as shown in Figure E. This solution provides a power factor at unity (minus the inductive part of the load itself). Even without the LTC function, EPower offers easy settings in every configuration (single phase and three phases) to switch automatically or on demand from Phase angle to zero cross to minimize the effect of phase angle and to maintain a power factor as high as possible. The load tap changer can be used on solution from 2 taps as described above and up to 4 taps to get the optimum result on the power factor, harmonic generation and global current distortion harmonic content (THDI). As shown in Figure F, if we reconsider the previous example at 50% power, the power factor will be 0.95 with three equidistant taps (same voltage between each tap) and 0.97 with 4 taps while it is 0.71 with the traditional solution. The power factor will always be above 0.9 from about 33% to 100% power with an EPower LTC solution
Phase Angle
Basic Facilities Charge Demand in kW Power Factor Demand Correction kW Demand Charge: $9.72 per kW Hour of operation Consumption per month (avg 30%) Energy Charge: First 100 kWh per kW Next 200 kWh per kW Monthly Energy Cost Annual Energy Cost Annual Savings
with 3 taps. With 4 taps, the range is even wider, as the power factor stays above 0.9 from 18% to 100% power.
Conclusion The load tap changer is a powerful solution for single phase applications that requires phase angle firing due to the load or for convenient matter. By dramatically improving the power
8.33
$9,545.04 720 130.000 kWh
25.00
33.33
$.0529/kWh $.0495/kWh
$5,832.00
$5,290.00 $1,485.00 $16,652.54 $199,830.48
$.0529/kWh $.0495/kWh
factor compare to a traditional phase angle solution, it results in limiting the harmonic generation thus reducing any associated issues that come with it. Even more important, it also reduces the Demand Charge of the utility to make some substantial savings. As for the PLM function, the new LTC function helps to improve the quality of the main power supply and
$5,290.00 $1,485.00 $12,939.50 $155,274.00 $44,556.48 -22%
ultimately reduces CO2 emissions. [MikaĂŤl Le Guern is Product Marketing Manager - Power Products, EUROTHERM] To save on your energy costs, contact Invensys Operations Management. Neil Hall neil.hall@invensys.com.au 03 8562 9855 www.invensys.com.au
Second Tap: 480V
First Tap: 240V
0.00
33.33
66.67
100.00
133.33
At 30% power, with a traditional Phase Angle solution, the average power factor is at a dramatic 0.55. In the opposite with EPower and the Load Tap Changer, the result describes in the table above is way better. Load Voltage V
0.00
Load Voltage V
700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700 8.33
16.67
25.00
33.33
0.00
700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700 8.33
16.67
Time (ms)
Pow er Factor
25.00
33.33
0.00
Pow er Factor
1.00
0.90
0.90
0.90
0.80
0.80
0.70
0.70
0.70
0.71
0.95
0.60
0.60
0.60
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0.50
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0.40
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0.00 0.00
0.00 0.00
0.60 Pow er (%)
0.80
1.00
0.20
0.40
0.60
0.80
Pow er (%)
FIGURE C: At 50% power, both taps are used with the LTC solution to maintain a power factor at 0.82 versus 0.71. (Vrms Load = 339V)
1.00
33.33
0.97
0.80
0.60
0.40
25.00
Pow er Factor
Pow er Factor 1.00
0.90
0.20
16.67 Time (ms)
1.00
0.82
8.33
Time (ms)
1.00
0.70
166.67
Time (ms)
Time (ms)
0.80
As shown here, if we reconsider the example in Figure E at 50% power, the power factor will be 0.95 with three equidistant taps (same voltage between each tap) and 0.97 with 4 taps while it is 0.71 with the traditional solution.
720 130.000 kWh
Load Voltage V
16.67
$332.50 600 kW >0.9 600 kW
Load Voltage V
700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700
0.00
$332.50 600 kW 0.55 982 kW
700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700
Load Voltage V 700 600 500 400 300 200 100 0 -100 -200 -300 -400 -500 -600 -700
Phase Angle with Load Tap Charger
0.10 0.20
0.40
0.60 Pow er (%)
0.80
1.00
0.00 0.00
0.20
0.40
0.60
0.80
1.00
Pow er (%)
This figure illustrates 50% Power with Load Tap Changer in Zero cross (Single Cycle).
MAY 2011 www.pacetoday.com.au 23
Monitor, analyse and control power and energy across the enterprise. Industries world-wide are facing escalating pressure to limit their energy consumption and justify every kilowatt expended â&#x20AC;&#x201D; to manage power and energy you must capably measure it. The Allen-Bradley Powermonitor range provides a full spectrum of plant energy monitoring and analysis. Additionally, where companies are challenged by regulatory compliance, penalty tariffs and tightening cost structures, these energy monitors deliver accurate information, so you can make the right decisions. For further information visit
www.RockwellAutomation.com.au www.RockwellAutomation.co.nz
PACE ZENITH AWARDS 2011 FINALISTS
Power and Energy Management FINALISTS
Thor Technologies
Fluke Australia & Mirvac Group
Green Board Balcatta, Western Australia Thor Technologies is dedicated to power surge protection for sensitive products ranging from home theatres to medical equipment. The company has introduced a Green Board (B12R) which is designed to save standby power wherever it is wasted by using an isolating switch/button on the desk or on the bench top. The dual purpose innovative product saves both expensive power and costly equipment in businesses and in the home market. The B12R from Thor Technologies can be integrated into most automated home installations. The Green Board features a save standby power and electricity with a flick of a switch, it is simple to use as it has no batteries, no set up, just a plug in remote switch to the side of the board. It has a supply voltage of 240/Vac 50 Hz, with a maximum current rating of 10 amps/2400 W (Va). The reaction time of the B212R Green Board is short and stated to be less than one nano second.
Troubleshooting Energy Efficiency in Buildings Sydney, New South Wales Mirvac Group turned to Fluke 1735 PowerLogger to help execute its energy efficiency initiatives. Designed to measure the most critical three-phase power parameters, the Fluke 1735 can log rms voltage, rms current, phase angle, voltage events, voltage and current THD, voltage and current harmonics up to the 50th, active power, reactive power, power factor, active energy, reactive energy, and more. With memory for up to 45 days of data, the Fluke 1735 can uncover intermittent or hard-to-find issues. The four current probes are connected with one plug; the instrument automatically detects, scales and powers the probes. These variable range current probes may be set to 15A, 150A, or 3000A for high accuracy in nearly any application. The colour screen provides instant confirmation that connections are correct, and then logging begins when the Record button is pressed.
Baldor Australia Cooling Tower Motor Drive New South Wales Baldor offers the power dense energy efficient technology of the RPM AC motor with permanent magnet (PM) rotor technology, to provide a direct drive motor for cooling tower applications. This motor is designed to replace conventional mechanical gear or belt drive speed reduction designs and provides the energy savings advantages of a variable speed control with the VS1 CTD cooling tower PM drive. The VS1 CTD software operates the Baldor PM cooling tower motor efficiently and reliably. One system is running under a controlled environment on one of two identical cooling towers at Clemson University. Both towers were instrumented and the traditional geared system was compared to the one converted to use Baldorâ&#x20AC;&#x2122;s Adjustable Speed Direct Drive Motor and Drive System. Each tower had the same 5 blade 18 ft diameter fan and the conversion was made in less than a day. Performance results measured an input kW power savings of 11.8% with high speed noise reduction from 82.3 dBA to 74.1 dBA.
MAY 2011 www.pacetoday.com.au 25
A proud sponsor of the “Young Achiever of the Year“ award.
NHP is a strong believer of investing in the future and nurturing home grown talent by providing our brightest stars with the tools and experience to be the best they can be. This is why NHP is a committed sponsor of the “Young Achiever of the Year“ award.
NHP Electrical Engineering Products
Sales 1300 NHP NHP
nhp.com.au
PACE ZENITH AWARDS 2011 FINALISTS
Young Achiever FINALISTS
Brad Shaw
Catherine Olima
Serck Controls In 2006 Brad Shaw was a graduate engineer and has now progressed to a senior systems engineer at Serck Controls Telemetry Competency Centre. Shaw plans and conducts professional engineering work without detailed supervision; his tasks include undertaking detailed design, programming and configuration of PLC, RTU and SCADA software.
Coca Cola Amatil Catherine Olima developed the operating guidelines for the equipment at the PET bottle self-manufacture project. She worked closely with Krones technicians and the company’s engineers to develop over 200 work instructions for use by operators running new lines. Olima’s work is now being transferred to all other Coca Cola Amatil locations in Australasia that are rolling out the new equipment.
Daniel Hancock
Jared Turner
Schneider Electric In January 2008 Daniel Hancock started at Schneider Electric as an industrial trainee. At 26, he is now the OEM systems and architects engineer. His current role also sees him as Schneider Electric’s Australian fieldbus and network expert. In addition, he also delivers training on these subjects and advises customers how to design and implement networks for optimal performance.
Coca Cola Amatil Jared Turner assisted in implementing the company’s PET self-manufacture project in Sydney. Turner took on a Line Leadership role and was responsible for developing the competence of the operators involved with the new lines. This project has allowed CCA to eliminate the need to purchase and transport bottles from another facility, reducing the environmental impact of truck movements.
Jason Ko Automotion Control Systems Jason Ko was ACS’ first engineer. Whilst trying to establish export business in 2009, he was placed in the position of CEO by the board to reduce company operating costs, set up the business to be completely focused on professional engineering, IT and manufacturing. Within the first calendar year, he turned ACS’ bottom line from a loss position to a month by month profit position.
Sebastian Karsas Proof Engineers Headquartered in Australia with global operations, Proof Engineers combines the art of road stabilisation with engineering principles to construct pavements that last longer and have environmental sustainability. Engineering director Sebastian Karsas headed the project: Real time monitoring solutions for Total Haul Road Management. Proof has saved many companies millions of dollars.
MAY 2011 www.pacetoday.com.au 27
Hoisting productivity without lowering safety.
ABB low voltage AC drives with direct torque control (DTC) provide smooth speed and torque control, cutting crane movement cycle times and optimizing crane capacity. Safety is enhanced via mechanical brake control with new productivity levels through quick and easy programming. To raise your productivity expectations to new heights, visit www.abb.com/drives
ABB Australia Pty Limited Phone: 1800 222 435 E-mail: drives@au.abb.com www.abbaustralia.com.au
PACE ZENITH AWARDS 2011 FINALISTS
Lifetime Achievement FINALISTS
Mario Dona Santos Mario Dona has 35 years experience in design, commissioning and operations of electrical, instrumentation and process control systems. He has commissioned major plant control systems with long term stability and minor rework. This experience was useful when the plant control systems were upgraded and the plant had to be rebuilt due to fire damage. Dona has contributed to the wider community by participating in the Standards Australia IT6-006-2 Industrial Process Control and Measurement IEC/AS 16508 & 16511 Functional Safety.
Don Erskine Industrial Conveying Don Erskine is the managing director of Industrial Conveying. He formed the company in 1979 and has overseen significant growth over the past 32 years. Erskine took an unusual step to ensure the company remained in Australian hands by splitting the entity into shares and handing it over to 200 of his employees. Considering the staff had been employed by the company since the beginning, Erskine believes it is important to reward loyalty and to maintain the ongoing existence of an important Bendigo company.
Ian Gibson IICA Ian Gibson works with the IICA as a chairman fellow review committee. Beginning as a Victorian division chairman, Gibson has progressed to federal president and now to his current role. Gibson was instrumental in the IICA gaining a government grant to support the IICAâ&#x20AC;&#x2122;s regional table top exhibitions. Being a very long standing IICA member, he has the knowledge and experience to do an excellent job representing IICA and the industry.
Colin North Major Furnace Australia Colin North joined Major in 970 as a project engineer and we appointed chief engineer in 1986. When the founders decided to close he purchased the business and continued to employ the remaining 22 staff. As MD he restructured the company and was then awarded significant large scale contracts. Northâ&#x20AC;&#x2122;s mantra to all within the company has been â&#x20AC;&#x153;attention to detailâ&#x20AC;?, an essential element when designing innovative equipment.
Frank Silberberg
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Group Instrumentation Frank Silberberg is director and founder of Group Instrumentation. Established in 1989, the company specialises in offering leading technology for emission monitoring and process control. Since cutting its offering to four products instead of the earlier 27, Group Instrumentation has seen a huge increase in sales and revenue. He always employs engineers, to ensure that his clients are well served. Silberberg plays an active role in supporting the activities of the IICA. He started at Honeywellâ&#x20AC;&#x2122;s Industrial Products Group and over the years has worked in workshop instrumentation, field service and engineering.
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MAY 2011 www.pacetoday.com.au 29
The PACE Zenith Awards recognise and reward companies that have demonstrated technological excellence and innovation.
NOMINATIONS ARE NOW CLOSED FOR TH ZENITH AWARDS. GOOD LUCK TO ALL THE THOSE WHO HAVE ENTERED. R YOU Y U B ETS TICK
NOW
PACE ZENITH AWARDS 2011 FINALISTS
Metal Products Manufacturing FINALISTS
Xstrata
Maxitec
ESP Dust Recovery Plant Mount Isa, Queensland The project objective was to eliminate the environmental and hygiene liability, as well as providing mechanism to unlock the significant value of an otherwise unattainable smelter by-product stream. Electrostatic precipitator (ESP) dust is formed as a by product of the Copper Smelting process. It is collected from the smelter gas stream in an Electrostatic Precipitator, where process water is added and the dust is either processed through the newly commissioned ESP Acid Leach Plant or it is diverted to stockpile. The solution was to implement a suitable processing method to deal with two sources of dust; the new arising generated during live smelter operations and from the historic stockpile. For a leaching process to be effective extremely tight control of pH is required to ensure that the values add base metals are recovered and that the other materials are separated, stabilised and disposed of correctly. The process is primarily to discard unwanted minor elements (e.g. As, Fe, Ca, Mg) and to recover the value add copper and gold contained within the ESP dust. Since the commissioning of the ESP leach and Agi-truck processes there has been a copper recovery of up to 98 per cent.
Conversion to ‘Lights Out’ Completely Automated Manufacturing Sydney, New South Wales Temperzone is in the initial phase of a multi-stage technology upgrade, by consolidating the company’s growth strategy on automated Finn-Power technology. This Finn-Power setup, with the Night Train FMS automated handling system soon to be at the hub and Maxitec technical support will ensure Temperzone processing sheet metal in more economical coiled form rather than individual sheets, with the option of running a 24/7 operation at will. The entire upgrade process is being conducted in stages. At the moment, Temperzone is adding a Finn-Power Shear Brilliance to its existing Finn-Power Shear Genius to further speed up the plant. At the same time, Finn-Power (through its Australian distributor Maxitec) has provided a blueprint for the layout of where a Night Train FMS system would fit in for a complete, 24/7 unmanned sheetmetal operation. Once the upgrade complete it is estimated to take one to two years in total. The integration of all these technologies will allow Temperzone to buy the coiled steel, put that on Night Train which feeds into all the punching, cutting and folding machines and at the end of the line leave finished components ready for assembly with no manual handling.
MAY 2011 www.pacetoday.com.au 31
Introducing a smarter way to calibrate temperature
Beamex® FB Field Temperature Block Beamex® MB Metrology Temperature Block Beamex introduces a smarter, more efficient and accurate solution for calibrating temperature. Beamex® has two different dry block series: the Beamex® FB Series Field Temperature Blocks and the Beamex® MB Series Temperature Metrology Blocks. The dry blocks in the FB Series are lightweight, high-accuracy temperature dry blocks for industrial field use. The dry blocks in the MB Series deliver bath-level accuracy for industrial applications.
Portable calibrators Workstations Calibration software Professional services Industry solutions
www.beamex.com info@beamex.com
PACE ZENITH AWARDS 2011 FINALISTS
Oil, Gas & Hydrocarbons FINALISTS
Emerson Process
Apex Optimisation and Woodside Energy
Intelligent Vessel Gauging System Geelong, Victoria Emerson installed a high-tech based system for level gauging in a LPG ‘bullet’ vessel at Shell’s Geelong refinery which is one of the first to be installed in Australia. The new radar technology replaces two old electro-mechanical gauges that were installed in 1978 and due for inspection. Opening the vessel for inspection can be complicated and expensive, with a radar gauge there are no components inside the vessel to measure the liquid level that may require servicing, and measurement verification can be carried out with the tank in operation. The new Rosemount Rex RTG 3960 gauge operates by sending a radar signal, so there are no moving parts. As well as measuring the LPG level, the system can also measure temperature and provide an alarm function. The Rex RTG 3960 is equipped with a pressure transducer which is integrated into the design of the gauge while the vapour temperature is measured with the connected temperature sensor. Temperature measurements are taken in both the liquid and the gas. After implementing the system a number of significant benefits including improved productivity, increased safety and higher profitability.
LNG Train Advanced Process Control Karratha, Western Australia Woodside approached Apex Optimisation early in 2010 to assist with a revamp of the existing Advanced Process Control (APC) on LNG (LNG4) Train 4 and the implementation of a new APC on LNG 5 (LNG5). The project kicked off in March 2010 after a functional design specification was completed. The revamp LNG4 APC was commissioned in late May 2010 and the new LNG5 APC was commissioned in September 2010. Site activities were completed with successful Site Acceptance Test in October 2010. A more sophisticated approach to optimiser functionality was added which enables the APC to pursue optimum process operation depending on specified product prices and allows the operator to modify the APC objectives to adapt to changing process requirements. One of the major benefits of the use of APC on process plants is improved consistency in how the process is managed.
Qenos
BJH Controls Condition Monitoring System for Gas Plant Vermont, Victoria BJH Controls has designed, constructed and configured a Rockwell Automation Condition Monitoring System for multinational Australian based company. The equipment has been installed to connect with twenty four velocity sensors mounted to monitor the inlet cooling fan drive assemblies in a gas plant on the sub-continent. The project objective was for BJH Controls’ to utilise Rockwell Automation XM series dynamic measurement modules to monitor vibration in rotating fan assemblies. These modules employ a 24-bit A/D converter which provides high resolution, making them suited for detecting machinery problems. Any fault that manifests itself through changes in the magnitude or phase of vibration can be detected by the advanced signal processing capabilities of the XM modules. These include most mechanical and electrically induced faults such as; unbalance, bearing wear, rotor cracks and rubs, instabilities such as oil whirl, preload conditions/misalignment and antifriction bearing defects. The scope of the work undertaken covers provision of a Condition Monitoring Panel and Hardware/Software, programming and logic to receive and process field inputs of vibration measurements and interface with a PSS and PCS.
Advanced Process Control and Plantwide Feed Maximiser Altona, Victoria The project objective was to provide a plantwide Advanced Process Control (APC) scheme to enable the Altona Olefins (ethylene) site operations department to take advantage of high feed availability scenarios. Maximising utilisation of available feed is critical to the ongoing profitability of the site. The ethylene production facility uses ethane from Bass Straight as the primary feed to the dual train, ethylene manufacturing plant. The APC includes all major unit operations at the Olefins site (ethane cracking furnaces, compression, fractionation and refrigeration systems). The site is controlled from four control consoles which consist of three process plants and one utility. The majority of the routine plant control is performed by a single panel operator at each of these changing setpoints and modes. The three process plant consoles were included in this project. The APC replaces around 90 traditional advanced control schemes and simplifies the overall running of the site.
MAY 2011 www.pacetoday.com.au 33
PACE ZENITH AWARDS 2011 FINALISTS
Water & Wastewater FINALISTS
UGL Infrastructure
Australian Bureau of Meteorology
St Marys Water Recycling Project St Marys, New South Wales This project produces high quality recycled water to conserve drinking water and enhance river health. Sydney Water and partners Deerubbin Water Futures developed the project as part of the NSW Government’s Metropolitan Water Plan which utilises dams, water efficiency, desalination and water recycling to secure the water supply. The $209 million project produces up to 18 billion litres of high quality recycled water a year and is the largest single contributor to achieving the water recycling target of 70 billion litres a year. The project supports river health by reducing nutrient levels in the Hawkesbury-Nepean river system.
Water storage iPhone application, Australia wide The Bureau of Meteorology launched a Water Storage iPhone application to give iPhone users access to information for more than 250 publicly owned water storages across Australia. This is the first time that current Australia-wide water storage information is available from a single source. Water storage levels and volumes can now be tracked for over 250 sites across the nation, with daily updates available for most of Australia’s urban and rural water supply systems. Users can find how much water is available in Australia and can see current water levels by percentage or volume in megalitres. They can also compare current levels with previous year, month, week or even previous day.
One Water Naturally
JS Melbourne Controls
WiWo-25 Belrose, New South Wales One Water Naturally designed a water conservation and management system WiWo (water in water out) to utilise a range of alternate water sources in preference to mains delivered reticulated water when an alternate source of non-reticulated water is available. The system enables seamless switching back to reticulated mains water once the alternative water source has been consumed or in the event of a power failure and ensures a continuous water supply. The product is the culmination of a combination of industrial automation technology with industrial water control products into a consumer level device.
Super Water Cannon Melbourne JS Melbourne designed a solution to deal with dust and the environmental impacts of spillage at a mine or holding area. The Super Water Cannon enables delivery of water to a wider area with a further throw than conventional water blasters. It has a greater flow once air pressure is added to the configuration. The product works by a series of specially angled, drilled holes in an internal ring. When the water assisted by some pressure passes through, it is sent into a circular motion, gathering speed and energy as it does so. The energy pattern is in a vortex shape and provides immense thrust when it exits the chamber.
CST Wastewater Solutions
UGL Infrastructure
Cadia Valley uses FAST Technology to Conserve Water Orange, New South Wales CST Wastewater Solutions implemented Fixed Activated Sludge Treatment (FAST) technology to assist Cadia Valley in purifying human and other waste water and enable it to be recycled on-site. Typically, an extended aeration plant has a mixed liquor suspended solids level (MLSS) of 3000-4000 mg/L. At this level the clarifier is being operated at close to the maximum solids flux. With FAST, the bacteria grow on the submerged media, and the mixed liquor circulating through the bacteria-laden media is clear. This reduces MLSS flow to the clarifier to approximately 100-400 mg/L and reduces the amount of solids flux.
Bootawa Water Treatment Plant Bootawa Dam, New South Wales MidCoast Water developed a Bootawa Water Treatment plant to improve Manning’s water supply scheme. The main processes and advancements to water quality treatment include membrane filtration, ozonation, Biological Acitivated Carbon (BAC) filtration, chlorine disinfection, final pH correction and fluoridation. A waste treatment system and chemical systems were also provided. The control system is designed to provide a fully automated solution with minimal operator input and remote access facilities through the Internet. The Bootawa WTP project has delivered a world class treatment facility.
CST Wastewater Solutions Vertical Screw Screen for Frucor Beverages Plant Manukau City, New Zealand Frucor choose a vertical screen from CST Wastewater Solutions to remove solid debris from factory wastewater before it is discharged into the sewer. Factory space was confined and the vertical screen provides an automated process that requires less labour than the previous ‘flat’ screen method, which necessitated regular removal of the screens by forklift, followed by hand cleaning. The vertical
screen is positioned between the below-ground sedimentary sump and the main sump, which both hold wastewater from the manufacturing plant at the Manukau City site. After the screen has removed solid material from the wastewater, it is pH corrected and discharged into the sewer. The solids are discharged into a bin for disposal. The system may be used in wastewater pits and pump wells. Frucor has saved time and money after implementing the vertical screen. MAY 2011 www.pacetoday.com.au 35
Your solution focussed partner for sensors and controls for automation
1300 365 088 sales.au@ifm.com www.ifm.com www.ifmefector.com.au/eshop
PACE ZENITH AWARDS 2011 FINALISTS
Automotive & Manufacturing FINALISTS
Ryan Aerospace
Coca-Cola Amatil Supply Chain and Krones Germany
Helimond Helicopter Simulator Taree, New South Wales Ryan Aerospace has designed, developed, manufactured and successfully marketed the world’s first low cost, reconfigurable helicopter simulator. The simulator has been used in various projects including military organisations, emergency services and commercial helicopter training organisations. After creating a prototype, Ryan decided to make a commercial version. The first order was from the Royal Air Force in the UK. The Helimond compromises of the main base unit made up of anti-torque pedals, cyclic (with a force trim function) and seat. To the left of the main unit, it has a ‘bolt on’ aircraft specific module. Ryan taught himself how to use 3D CAD modelling and moved to an advanced stage very quickly. This allowed him to design the whole product. He also discovered a product called Maytec by using the Industry Capability Network (ICN). This is an aluminium profile building system, which usually is used for making tables, work benches and conveyor stands. Using Maytec significantly reduced the cost of manufacture and allowed flexibility to 'add' new components or change existing ones without too much trouble or expense.
PET Bottle Self-Manufacture Northmead, New South Wales Coca-Cola Amatil Supply Chain in conjunction with Krones Germany has designed, installed and commissioned new production lines at its production facility at its Northmead facility in Sydney. The two new lines incorporate technology that enables PET bottles to be blown and immediately filled on line. The objective of the project was to make Coca-Cola Amatil self-sufficient in the manufacture of one of its key packaging requirements. According to the company, this has eliminated the need to purchase and transport bottles from another facility reducing environmental impact of truck movements as well as increasing the flexibility and responsiveness of the production lines to new product development. As part of the project, Coca-Cola Amatil has also conducted an 'operational readiness' stream of the project that has meant that existing staff were extensively retrained and supported in learning the new, state of the art equipment. Coca-Cola Amatil Supply Chain completed this project in under twelve months from the placement of orders to the completion of acceptance tests.
Robotics Automation and The Dulux Group
Precision Mechatronics and Beckhoff Automation
Robotic Compositing, Handling & Stocking System Dandenong South, Victoria The project objective was to explore a potential for an automated solution to preventing harmful dust to employees. Staff were required to wear hot and uncomfortable respirators, bodysuits and other safety wear whilst at the same time working accurately with each powder ingredients. Dulux Group and Robotics Automation worked together to find a solution, developing the Centralised Make-up Facility. This project consisted of the Major Materials Robotic Loading System, the Minor Materials Robotic Loading System and a SCADA system to govern the total solution, in addition to taking each unique batch order via a database management system connected to Dulux Group’s SAP system and staff operated by HMI touch-screens. The three Robotic chefs (Motoman HP165-100 models) tasks is to handle, pour, mix or more basically to cook up perfect-powder-coating product to order. It races back and forth along two 20m long tracks. The system has improved safety by redeploying nine employees from a hazardous and uncomfortable work environment, in addition to eliminating OH & S incidents in the process.
Ink Cartridge Filling System North Ryde, New South Wales Precision Mechatronics developed an ink cartridge filling machine that fills five 50 ml ink cartridges every 20 seconds. The demanding task required a control system which involves the PC and EtherCAT-based Beckhoff control platform, with integrated Motion Control functionality. Four Beckhoff AX5203 EtherCAT Servo Drives and eight AM3024 servomotors were installed in the ink cartridge filling machine. A rotary table design enables a large number of processes to be executed simultaneously. The pre-requisites are the large storage capacity and the high processing speed of the EtherCAT-based control components. The machine can fill five containers simultaneously with different coloured inks, accomplished by a mechanism that rotates step-by-step, driven by a Beckhoff servomotor. The processes are executed in parallel, to maintain the required cycle time of approximately four seconds per container. After the inks are filled, the containers are sealed and their quality analysis data stored, before they are set down on the discharge conveyor. The heart of the controller is formed by a Beckhoff C6920 control cabinet Industrial PC with TwinCAT PLC NC I software.
MAY 2011 www.pacetoday.com.au 37
Whether you build it... or move it Global competition. Higher costs. Increasingly stringent environmental standards. To meet your challenges you need to increase throughput and efficiency while minimising manufacturing costs, maintaining high reliability; within tight deadlines. Rockwell Automation offer you a range of solutions which can improve your operation and gives you a competitive advantage. For further information visit www.RockwellAutomation.com.au www.RockwellAutomation.co.nz
PACE ZENITH AWARDS 2011 FINALISTS
Transport, Power and Infrastructure FINALISTS
Xstrata Copper
AnaeCo and Hero Engineering
ESP Dust Recovery Plant Mount Isa, Queensland The project involves the electrostatic precipitator (ESP) dust which is reclaimed from the stockpile, transported and discharged into the leaching process in either the Waste Slurry Tank with newly formed dust from the smelter or into the Copper Solution Tank in the Leaching Plant. The reclaim process for the stockpiled dust utilises a purpose built 15m3, 316 stainless steel agitated mixing bowl mounted on a trailer. The slurry pumped into the Waste Slurry tank is leached, neutralised and the copper and gold recovered in the ESP recovery plant.
DiCOM Project Development Perth, Western Australia AnaeCo designs and operates Alternative Waste Technology (AWT) plant to process Municipal waste to produce saleable compost, recyclable and energy. Redirection of waste from landfill is processed using the DiCOM bioconversion process developed and patented by AnaeCo. The company had to demonstrate the DiCOM process as a viable AWT, requiring from the outset electrical and control systems for the Demonstration facility and later the commercial scale plant. Hero Engineering worked with AnaeCo to develop the Demonstration plant (stage 1) Electrical, control and functional safety design during 2009. The performance trials received independent engineer’s validation of the DiCOM process in regards to product quality, effluent control (water, noise and odour emission), demonstrated plant safe operation and robust engineering processes. During Stage 1 commissioning, the scoping for a 55,000 tpa AWT commercial scale project (stage 2) was undertaken by AnaeCo and Hero Engineering. Stage 2 represents a 1000 time scale up of stage 1 and reuses process equipment and control and safety systems from stage 1. As a result AnaeCo have accepted DiCOM as a solution to process Municipal waste.
FreshBins Warnambool, Victoria FreshBins developed a mobile system that reduces water usage, whilst removing environmental pollutants from the process of cleaning ‘wheelie bins’. The sanitisation process is completed in seconds, allowing the operator to process over 1000 bins in an eight hour shift. The company used a ‘Generation 3’ Unit which incorporates a mobile three-dimensional sensing robot, installed and programmed by Machinery & Robotics (MAR). MAR combined new sensor and collector technology with an effective ozone sterilising system.
TruckOn Project Partners (NICTA, Braetec, Cohda Wireless, CPE Systems, ResTech) TruckOn – Overhead Collision Prevention Sydney, New South Wales TruckOn is a forward-looking ‘proof-of-concept’ project to demonstrate how emerging wireless vehicle communication technologies could prevent accidents of over-height truck collides with tunnels, overpass or enclosed bridge. The system works when an over-height vehicle breaks a height detection beam, a road side control system uses wireless vehicle communications to transmit to all vehicles in the vicinity the GPS location and exact time the beam was broken.
iOmniscient China Fast Train Project China A Safety System was implemented in China by Australian company iOmniscient, for the China Very Fast Train Project. Drivers were unable to see if there was an obstruction on the track. The Chinese Ministry of Railways decided to use Video Analysis to detect people or objects that might intrude on the tracks. iOmniscient installed over 3,000 cameras, its products are armed with Nuisance Alarm Minimisation System that can differentiate between objects and shadows.
Level Indicators Level Indicators that are easy to read whatever way you look at it. Made in Oz for fast delivery. They require no power and no maintenance with nothing to wear out. What else can you buy that can make that claim?
FreshBins and Machinery Automation & Robotics
Control Components U19 15-23 Kumulla Rd, Miranda NSW 2228
Ph +61 2 9542 8977 • Fax +61 2 9542 7978 Email: help@controlcomponents.com.au www.ccezy.com.au MAY 2011 www.pacetoday.com.au 39
Increase production
Manage operating costs
Maximise safety
Reduce design costs
Optimise your mine’s performance with a truly integrated solution Introducing mining process optimisation solutions powered by EcoStruxure Discover a host of benefits when you choose an integrated Schneider Electric solution for power distribution, process and machine control, security and managed services.
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Power Management Process & Machine Management Security Management
Reduced design and implementation costs Tested, validated and documented architectures greatly reduce system design costs and offer proven reliability. Scalability permits installations to be expanded when demand trends shift, ensuring tightly knitted solutions, precisely integrating all mining processes and simultaneously reducing resource wastage.
Managed consumption and operating costs Substantial operating savings can also be made through the implementation of energy efficient solutions and maintenance management services which, when combined, reduce consumption, process downtime and contribute to environmental sustainability.
Maximised safety, security and uptime Integrated safety, monitoring and intrusion security systems not only allow for uninhibited visibility but also reduce accident downtime. As with all solutions across our business, people safety remains at the core of our methodologies. For further information as to how you can benefit from true integration, visit www.schneider-electric.com.au or call 1300 369 233.
Power Process & Machines Security
PACE ZENITH AWARDS 2011 FINALISTS
Mining, Minerals & Exploration FINALISTS
Xstrata Copper
Proof Engineers
Copper Refinery Cathode Nodule Catcher Townsville Copper Refinery, Townsville, Queensland The refinery needed to cut labour and safety issues when cleaning a cathode stripping machine. The solution was to implement a system that cleans itself by gravity, the false floor plates were removed and a nodule catcher installed. Copper waste ends up in the nodule catcher, which is then emptied bi-weekly.
Real Time Monitoring Solutions for Total Dust Management, Rolling Resistance and Road Deterioration The company pioneered the development of real time onboard haul truck systems to measure road deterioration and rolling resistance. With this information, management can decide on maintenance procedures before road quality is badly affected, and can save companies millions of dollars in maintenance.
J. Smith & Sons
Boulder Buster Australia
Smith Mk4 Hydrapede Dolly West Turner Syncline Mine, Western Australia The Smith Hydrapede is a powered dolly which enables mining road trains to haul large amounts of mineral over long distances from the mine to the R.O.M. or product endpoint. A CANbus network and a custom-built software program are used to fuse communications between Hydrapede components.
Boulder Buster System Jindabyne, New South Wales The Boulder Buster System has been used as an alternative rock breaking tool and problem solver for underground mining (excluding coal) and open cut mining. It can be used in different applications including; clearing draw points, shuts, crushers, grizzlies and dealing with oversized rocks.
CST Wastewater Solutions & Newcrest Cadia Valley Cadia Valley uses FAST Technology to Conserve Water Orange, New South Wales Newcrest introduced a high efficiency, low maintenance waste water treatment system at its Cadia Valley Operations (CVO) to purify human water and other waste water, in addition to enabling it to be recycled on-site. The Fixed Activated Sludge Treatment (FAST) will extend the lifespan of CVO for at least 20 years.
Alcoa Australia Residue Reuse Booragoon, Western Australia Every six tonnes of bauxite makes two tonnes of alumina. Alcoa has developed a number of bauxite residues by-products which will allow the company to put the residue to sustainable use. Red Sand is literally crushed rock that is red in colour. Testing has shown Red Sand can be used as a general fill material.
Hawk Measurement Systems Gladiator Self-Cleaning Acoustic Level Switch Melbourne, Victoria Hawk designed an Acoustic Switch for continuous operation in dusty, wet environments where other level measurement technologies fail. The acoustic switch is a dual transducer system unaffected by vibration, dust, water and high dielectric atmospheres. The system uses high power and low frequency. MAY 2011 www.pacetoday.com.au 41
EVENTS & EDUCATION
WHAT’S ON
REVIEW
Getting the Design Right and the Right Design
MATLAB Technology Tour 5-19 May 2011, 5 cities www.mathworks.com.au/MTT Ozwater ‘11 9-11 May 2011, Adelaide www.ozwater11.com.au National Manufacturing Week 2011 24-17 May 2011, Melbourne www.nationalmanufacturingweek.com.au Process Analyser Sampling System Training 6 & 13 June 2011, Melbourne & Perth www.swagelok.com / 08 8369 0899 PACE Zenith Awards 2011 16 June 2011, Sydney www.pacetoday.com.au/awards 7th Australian Workshop on Acid and Metalliferous Drainage 20-24 June 2011, Darwin www.jktech.com.au
For daily updates visit www.pacetoday.com.au
‘Sketching User Experiences: Getting the Design Right and the Right Design’ By Bill Buxton Elsevier $62.95 This book covers sketching and early prototyping design methods suitable for dynamic product capabilities: cell phones that communicate with each other and other embedded systems, smart appliances, and things you only imagine in your dreams. Thorough coverage of the design sketching method which helps easily build experience prototypes without the effort of engineering proto-
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AWAY
types which are difficult to abandon. The book reaches out to a range of designers, including user interface designers, industrial designers, software engineers, usability engineer, product managers and others.
‘Pipeline Rules of Thumb Handbook, 7th Edition’ By E.W. McAllister Elsevier Price: $155.95 This classic reference has built a reputation as the ‘go to’ book to solve even the most vexing pipeline problems. Now in its seventh edition, Pipeline Rules of Thumb Handbook continues to set the standard by which all others are judged. The 7th edition features over 30 per cent new and updated sections, reflecting the exponential changes in the codes, construction and equipment. The seventh edition includes:
recommended drill sizes for self-tapping screws, new ASTM standard reinforcing bars, calculations for calculating grounding resistance, national Electrical Code tables, Coriolis meters, pump seals, progressive cavity pumps and accumulators for lubricating systems.
You could win one of these engineering textbooks by answering the following simple question: On which page of this magazine will you find "GTAW" mentioned? Email your answer to kevin.gomez@reedbusiness.com.au
Both books are available direct from Elsevier Australia Customer Service, 1800 263 951 or www.elsevierdirect.com
IICA NEWS & VIEWS
Australia is rapidly being left behind Instrumentation education cannot continue as a ‘tack-on’ to other courses, writes Dirk Kuiper. EVER increasingly, sophisticated advanced technological innovation is without doubt the key driving force behind virtually every imaginable area of human endeavour that derives from invention, design, production and manufacturing to finished product. And the common thread which binds all those myriads of technologies is their dependence on ever more advanced instrumentation and control systems to ensure that all the billions of diverse end products in whatever field you can imagine, are all able to function safely and deliver the solutions for which they are designed. This trend will not peter out, but as with all previous technological revolutions, will demand more and more specialist skilled people to progress and 42 www.pacetoday.com.au MAY 2011
manage the inevitable surge of even newer technologies. The question the Institute of Instrumentation, Control and Automation Australia (IICA) is posing is this: are our education institutions, schools, TAFEs and Universities prepared and ready for the kinds of skills needed now and in the future? Or are they – as they have always been – reactive and always playing catch-up to emerging needs? The IICA believes that it is more critical than ever for tertiary organisations – be they Universities or TAFEs – to address the need for stand alone courses and qualifications with primary focus on instrumentation, control and automation. In the majority of Universities, these critically vital specialist areas tend to be
tacked on as just ‘add-ons’ to existing Chemical, Electrical, Mechanical and other traditional engineering streams. There are fortunately a very small number of Universities that are beginning to offer stand-alone specialist instrumentation type courses and the IICA applauds and commends them. Likewise, in the TAFE sector, the IICA sees existing training packages without specialist instrumentation and control system contents on centre stage of curricula contents. Such deficiencies and gaps, short sell the kinds of training that aspiring technicians need to meet the needs of the ever more sophisticated technological working environments they will face. It is no accident that the list of skills shortages constantly lists trained techni-
cians in the broad instrumentation areas. The IICA thinks this is simply not good enough if Australia wants or sees itself playing an active role on the international stage where most other developed countries are already leaving Australia behind in their investment to preparedness for future needs arising from rapid change. The IICA’s objective is to further the science and practice of measurement, instrumentation and control. The institute also fosters high standards for design and manufacture of instrumentation and of control techniques. [Dirk Kuiper is IICA Federal President.] IICA 1300 781 715 www.iica.org.au
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