PACE - Process & Control Engineering - November 2012

NOVEMBER 2012 | VOL.65 NO.10

How to flatten regulator flow curves Operate the regulator on the flattest part of a curve where it will maintain constant pressure even with significant changes in flow.

Post Print Approved PP255003/00539

Technology Update 13

Nominations are now open for the 2013 10th Annual PACE Zenith Awards, to be held in Sydney on Thursday 13 June 2013.

A total of 11 awards will be up for grabs on the night, highlighting company’s innovation and excellence in engineering and technological projects.

All finalists will receive free publicity in PACE magazine and two free tickets to the gala dinner where the winners will be announced.

For more information please visit www.pacetoday.com.au/awards

PROUDLY SPONSORED BY

CONTENTS

Published monthly by Reed Business Information Pty Ltd

Tower 2, 475 Victoria Avenue Chatswood NSW 2067 Locked Bag 2999 Chatswood DC NSW 2067 Tel: (02) 9422 2999 Fax: (02) 9422 2977 ABN 80 132 719 861 Associate Publisher: Martin Sinclair Email: martin.sinclair@reedbusiness.com.au Editor: Kevin Gomez Tel: (02) 9422 2976 Fax: (02) 9422 2722 Email: kevin.gomez@reedbusiness.com.au

IN THIS ISSUE

Deputy Editor: Isaac Leung Tel: (02) 9422 2956 Email: isaac.leung@reedbusiness.com.au Group Sales Manager: Tim Richards Tel: (02) 9422 2818 Mobile: 0420 550 799 Email: tim.richards@reedbusiness.com.au

07

QLD Sales Manager: Sharon R. Amos PO Box 3136, Bracken Ridge, QLD 4017 Tel: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 Email: sharon.amos@reedbusiness.com.au Graphic Designer: Justine Dunn Email: justine.dunn@reedbusiness.com.au Production Co-ordinator: Tracy Engle Tel: (02) 9422 2707 Fax: (02) 9422 2722 Email: tracy.engle@reedbusiness.com.au

Printed by: GEON 20 Baker Street, Banksmeadow NSW 2019 Tel: (02) 8333 6555 SUBSCRIPTION: $99 pa incl GST OVERSEAS SUBSCRIPTIONS: NZ: $A109 pa & OS: $A119 pa CUSTOMER SERVICE: 1300 360 126

Copyright © Reed Business Information 2012 All rights reserved. No part of this publication may be reproduced or copied in any form or by any means without the written permission of the publisher.

18

25

22

News Analysis 7

Technology Report 18

Case Study 25

Need to integrate Getting more out of less and dealing with the skills drain were some of the themes for the Schneider Electric 2012 Users Conference.

Detect cracks in turbomachines Machinery vibration monitoring requires strategically located vibrational sensors to capture the vibration.

Transform waste into energy Anaerobic waste water digestion technologies respond to industry’s need to clean up their waste water.

Application Note 22

IICA Corner 30

Viewpoint 10

Solutions for ring-geared mills Low speed drive solutions are quickly increasing their share of the market for ring-geared mill drives.

Planning for the future The Institute of Instrumentation, Control and Automation will work through and prioritise key issues for 2013.

Asset management Reliability solutions can offer unique value propositions for the process industries.

ON THE COVER

OFFICIAL MAGAZINE OF:

NOVEMBER 2012 | VOL.65 NO.10

How to flatten regulator flow curves Operate the regulator on the flattest part of a curve where it will maintain constant pressure even with significant changes in flow.

Average Net Distribution Period ending March ‘12 6,849

Post Print Approved PP255003/00539

Technology Update 13

BECKHOFF implements open automation systems based on PC Control technology.

The product range covers Industrial PCs, I/O and Fieldbus Components, Drive Technology and automation software.

Products that can be used as separate components or integrated into a complete and seamless control system are available for all industries.

The Beckhoff “New Automation

Technology” philosophy represents universal, open control and automation solutions that are used worldwide in a wide variety of different applications, ranging from CNC-controlled machine tools to intelligent building automation.

The growing presence of Beckhoff in more than 70 countries ensures consistent support around the globe. www.beckhoff.com.au

A NEW compact machine control platform that has it all.

The NEW Allen-Bradley midrange control platform equipped with Allen-Bradley® products from Rockwell Automation provides all the control you need and at a competitive price. r CompactLogix control platform provides scalability from 2-16 axes of motion r Standardisation of platform simplifies design, operation and maintenance r EtherNet/IP connectivity for network standardisation and enhanced data management r Integrated Motion and drives over EtherNet/IP

Find out more at www.scalabletechnology.asia/PACEAUS

DOWNLOAD OUR MIDRANGE GUIDE

NOW

NOVEMBER 2012 www.pacetoday.com.au 3

COMMENT

WHAT’S ON

EDITOR’S MESSAGE

Are we really a happy bunch?

PAS Alarm Management and HMI Course 12-13 November 2012, Perth www.apex-opt.com Machine Safety Training 13 November 2012, Brisbane brisbane.events@inaco.com.au FOUNDATION Fieldbus Course 13-14 November 2012, Perth training@seacove.biz

Kevin Gomez Editor

Safety Instrumented Systems (IICA/ISA) 14 November 2012 www.iica.org.au/info/education Certified Profibus Training 26-30 November 2012, Melbourne profibusaustralia.com.au For daily updates visit www.pacetoday.com.au

Next Issue • Fluid Handling • Sensors & Analysers • Process Control in Food & Pharmaceuticals • Wireless Technology

A RECENT US survey conducted by online job site, CareerBliss indicated that field technicians and process engineers are among the happiest workers in that country. It will be interesting to hear from our readers if the same is likely to be true for engineers and technicians in Australia.

The process engineers surveyed claimed their ‘happiness’ came about because their jobs combine high technology with hands-on problem solving.

That settled, we are encouraging all those happy engineers out there to get their entries ready as we open nominations for the PACE Zenith Awards.

The Awards event in 2013 will be a significant milestone as

it will be the tenth one. We encourage you to be a part of the celebrations.

As I write this, an interesting report from professional services company, pitt&sherry, just landed on my desk. The report states that the demand for electricity continues to decline through Australia.

The September 2012 numbers mentioned, are in line with the trend that has been continuing for the past two years.

Perhaps all the energy saving initiatives, smart engineering and, of course, higher electricity prices, are combining to rein in demand.

It is also heartening to see a steady growth in the contribution from renewable and

clean energy sources. In South Australia for example, 26 per cent of energy demand was provided by wind and 49 per cent by gas.

In Victoria, the billiondollar Macarthur wind farm has come online for the first time. The initial output is very small but when complete, at 420 MW, it will be the largest wind farm in the Southern Hemisphere.

But more needs to be done and effective energy management will be a talking point in our industry for some time to come. kevin.gomez@reedbusiness.com.au

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

CAREER

An alternative path to personal growth and success

BY JIM PINTO HOW does an individual get paid in the stolid management environment of large automation companies?

The usual path to personal advancement is to switch jobs – moving to higher management levels in competitors and perhaps finally achieving a VP-level position. But, beyond the titles and salary increments, it’s seldom worth the effort. To get on the fast track, my advice is to start your own company, or become part of a founding group with

significant equity participation. No big company can match the money you can potentially make as an owner.

A successful startup requires a well-developed business plan. Don’t go it alone; the best results come with founders who have complementary skills: marketing/sales, engineering and operations. The founders should be intelligent, passionate and motivated by shared ownership. They should maximise their shared equity through reduced expenses with shoestring

You’re at the top of our world...now stop right there Software Toolbox wants to turn you upside down with our excellent products and service. We may sound funny, but we talk sense.

Learn how our software connects your devices and applications. Put the right data in front of the right people at the right time and feel free to contact us and discuss your needs. At the end we are here to help you establish the best connections!!!

-VY HSS `V\Y ULLKZ JHSS >VUKLY^HYL (\Z[YHSPH VU VY PUMV'^VUKLY^HYL JVT H\

4 www.pacetoday.com.au NOVEMBER 2012

budgets. The frills can be added when growth and success is attained.

The primary aim is to find growing customer needs and satisfy them profitably. With a little bit of luck and a lot of hard work, your company will grow profitably, be acquired and the founders will become millionaires.

No big company can match that.

It worked for me! If you fail, you can always retire to the safety of a cubicle in a large corporation.

Jim@JimPinto.com

Integrating People, Processes and Information 4HUHNLTLU[ 4VK\SHYP[` :JHSHIPSP[` 6WLUULZZ *VTTVU <UPM`PUN 7SH[MVYT

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

NEWS

ROBOTICS

Swinburne University wins again SWINBURNE University of Technology was awarded first place in the National Instruments Autonomous Robotics Competition. Their robot, Frogstar, beat 17 other teams from across Australia and New Zealand and took out the robotics prize for the second consecutive year.

Eighteen university teams from Australia and New Zealand competed in the ‘Search and Rescue’ themed final.

The competition emulated the use of robotics in situations dangerous to humans such as an earthquake or battlefront. The UOW Robotics Team from the University of Wollongong was the runner up in the competition.

In the final, the robots navigated a course filled with obstacles signifying rubble to source two cubes representing injured or trapped humans. The cubes then had to be collected and relocated to safety. Matej Krajnc, Managing Director for National Instruments Oceania said the competition allowed students to demonstrate their mechatronic and engineering skills on an international level.

“Each of the 18 teams competing in the final successfully completed four milestones over the past six months to qualify. The competition gives students valuable experience working with advanced technologies and can broaden

WINNERS: The team from Swinburne kept their robot small and compact and won the robotics prize for the second consecutive year. their career path options, as such we saw a notable increase in participants for the 2012 competition,” said Kranjc.

Ben Smith, leader of the winning Swinburne University of Technology winning team, said the competition was a great opportunity to get hands on experience in robotics.

“The NI Autonomous Robotics Competition (ARC) has been a great opportunity for us to exercise the

practical knowledge we’ve gained from our studies and to interact with other engineering and mechatronics students.

Having won in 2011, we decided to keep Frogstar small and compact rather than become too ostentatious, and it was definitely a decision that worked in our favour,” said Smith.

Swinburne University of Technology was awarded the first place prize of $3000, the University of Wollongong

was awarded $1500 and a bonus prize of $500 was awarded to University of Newcastle who were declared the winners of the most aesthetically pleasing robot award by the NI ARC judges.

All of the teams that successfully completed the competition final get to keep the development kit, valued at over $27,000. John McIntosh, Victorian President, Engineers Australia and Professor Zhihong Man, Head of Robotics and Mechatronics at Swinburne University of Technology judged the competition.

Of the 24 teams which started the competition in March, 18 were able to complete four milestones to qualify for the final.

Universities which competed in the final were: Queensland University of Technology; University of Newcastle; University of New South Wales; University of Technology Sydney; University of Wollongong; Curtin University; Griffith University; Charles Darwin University; RMIT; Swinburne University of Technology; University of South Australia; University of Auckland; Auckland University of Technology; University of Canterbury; Massey University; Victoria University of Wellington. australia.ni.com/ni-arc

How do you

select the right sensor

for applications with multiple types of metals? ©2012 TURCK

6 www.pacetoday.com.au NOVEMBER 2012

askTURCK.com.au

NEWS ANALYSIS

CONFERENCE

Focus is on getting more from less

BY ISAAC LEUNG THE Schneider Electric PlantStruxure NOW! 2012 Users Conference took place on the Gold Coast from 9 to 11 October 2012. The event featured more than 45 case studies, business and technical sessions presented by industry experts.

The user conference also included a “marketplace” featuring a demonstration wall dedicated to the PlantStruxure architecture, solution booths for the water, mining and food and beverage industries, tech demonstrations, and Schneider Electric partners ready to discuss their offerings with attendees.

According one of these partners, Scott Henson from Niobara R&D, his company has been associated with Schneider Electric for almost 20 years, and is a platinum member of the Collaborative Automation Partner Program.

His stand displayed the company’s latest Quantum communication modules, modules for the Momentum platform, and older legacy migration tools. “Most of our products deal exclusively with Schneider Electric backplanes and protocols,” Henson told PACE. “Many of our solutions deal with tying in legacy Schneider Electric equipment into new hardware, so we are working on making that more seamlessly integrated into PlantStruxure PES.” Henson said the response from the event was very good. “The customers who come by to visit are very knowledgeable and are well targeted for our products. I am very happy with the response so far,” he said.

Another company at the marketplace was Pepperl+Fuchs, a hazardous area provider company which does the interfacing work for Schneider Electric.

David Prasser was at the stand to introduce the company’s Profibus PA devices for hazardous and general purpose use, as well as a range of remote I/O, and a food-grade IP66 HMI. “There is a lot of activity here, and a lot of people are calling by and have a look at what we have here, and what we are doing with Schneider Electric,” Prasser told PACE. The conference opened with an overview of the business by Christopher Crowe, Schneider Electric’s senior

MARKETPLACE: The user conference featured a demonstration wall dedicated to the PlantStruxure architecture. vice president for sales international industry business.

Speaking about the rise of the newer economies, Crowe emphasised the Paris-headquartered company’s history of diversifying away from its traditional European roots to become a global entity, and said this is a continuing process which insulates the business as a whole against regional fluctuations.

“Regions like East Asia, central Africa and southern Africa are becoming a hunting ground for a lot of large mining companies trying to get a sense of the opportunities in the new economies,” Crowe said. “Our job is to anticipate that and ensure we have people going to those regions and supporting the growth there.”

While Schneider Electric is focused on growing its areas of expertise through the acquisition of innovative companies, it also invests around a billion dollars a year in pure research and development, evolving its technologies and products to keep up with a continuously changing

competitive landscape and industry.

Where the company was focused on electrical distribution and industrial automation prior to 2000, it has since made strategic acquisitions and entered into other areas, as the dynamics of customer demands changed.

Notable recent acquisitions by Schneider Electric aim to fill specific gaps in the business. For example, Telvent, for grid, oil, gas and water management, SolveIT for logistics, planning, decision making and scheduling, and 7T for water distribution network management, monitoring and optimisation.

A core part of the event was the introduction of the PlantStruxure offering from Schneider Electric, with the afternoon of the first day dedicated to detailed sessions and demonstrations around the offering.

Scott Wooldridge, vice president of Schneider Electric’s industry business, noted that the acquisitive strategy, while yielding many strengths for the business, also resulted in overlaps

in solutions and technologies.

Additionally, the company recognised the challenges facing today’s process industries, including the need to continuously reduce downtime, decreasing time to market, reducing waste, and coping with a dwindling talent pool.

To simplify the offerings and integrate the various process automation solutions, the company launched PlantStruxure, which allows process control customers to connect field, process , plant and enterprise levels within their businesses.

The technology connects hardware, software and Ethernet-based architecture, and is based on tested and proven architectures for process and energy management. A more specific solution, PlantStruxure PES (Process Expert System) brings together the best of PLC/ SCADA and DCS, along with a single database and direct cross referencing of process objects. > Active energy management NOVEMBER 2012 www.pacetoday.com.au 7

NEWS ANALYSIS

is embedded into every layer of PlantStruxure PES. The central database, along with a centralised library structure, means operators can now directly look up any objects related to a particular process or object, as well as documentation and manuals relating to any piece of equipment.

According to Wooldridge, while PlantStruxure will provide integration and consolidated control over all of Schneider Electric’s process environments, the technology is also focused on optimising energy use, one of the key themes running through the user conference.

Taking up the theme was keynote presenter Dr Jonathon Ralston, research leader in CSIRO’s Mining Technology Group, who addressed the question of how technology can meet the new demands of industry.

According to Dr Ralston, science and technology have a big role to play as industry and governments realign themselves to focus on key issues like energy and resource use efficiency, IT, environmental challenges and new economies on the rise.

To ensure sciences developed by research bodies like CSIRO actually make it into the industry to have a positive impact on processes, Dr Ralston stressed the need for like-minded industry players to take on new technologies and close the gap between research and industry.

By way of illustrating how CSIRO applies science and technology to enhance processes within the industry, Dr Ralston looked at how the organisation improved longwall coal mining.

Longwall coal mining is traditionally a dusty process, with operators standing next to the shearer to direct it along the seam. CSIRO took components from an earlier military project and introduced it into the mining operation, allowing it to determine the location, orientation and motion of the shearer.

This then enabled visualisations of the machine, which were integrated into a model, accurately representing the process.

This took operators away from the dusty front lines of longwall coal mining, allowing informed decision making and guidance from relative safety. Productivity was boosted by 10 to 25 percent, and since its introduction in 2007, nearly 50 percent of Australian long wall operations 8 www.pacetoday.com.au NOVEMBER 2012

COMPLEMENTARY: The marketplace allowed attendees to explore a range of Schneider Electric partner technologies. now use the technology.

Dr Ralston said the next wave of opportunities for improving processes lay in the use of interconnected information, intelligence management, improving reliability, situational awareness, remote centralised operations and improved human-systems interaction.

PACE magazine was also present on the second day of the conference, when the program was split into the three streams dedicated to Water & Wastewater; Mining, Minerals & Metals; and Food & Beverage Manufacturing.

The common thread was the intelligent use of technology to deal with the challenges of scarcity and the drive for ever greater efficiency in terms of process speeds and also resource usage.

In the case of water, for example, presenters like Dominique Gayraud, Schneider Electric’s solutions vice president for Water & Wastewater, pointed out the disparity between the rapid rise in energy costs and the relatively low cost of water as one of the key challenges facing the industry.

“Energy is the first significant cost component for water plant operators. It represents a third of the total operating cost of water management (and 56 percent of the operating cost for reverse osmosis desalination),” said Gayraud.

“This will not decrease because the processes will be more complex, requiring more energy for more complex filtration. We also have time constraints associated with reuse of water, so speeding this up will also require more energy. Expanding networks will also increase energy consumption.

“In an environment of rising costs but steady water prices, energy savings become a must. Energy savings provide a real cost saving opportunity,” he noted.

According to Gayraud, Schneider Electric is working together with partners and continuing development of its technologies to reduce capital expenditure and operational expenditure. It is also working on solutions to detect and reduce leakage, optimise infrastructure management, and adapt to weather conditions.

Other steps which could be taken in conjunction with the deployment of new technologies include fixing the basics by making the infrastructure energy-aware.

Programs like Schneider Electric’s EnergySTEP involve building accurate models of what the plant is doing, from the low SCADA level up through to the enterprise level, then optimising the obvious targets, before embarking on continuous tracking and optimisation,

using a variety of measures such as automation.

In the mining stream, a major concern was remaining cost-competitive in the global marketplace, especially with the emergence of new economies as power players in the low-cost resources space.

Ian Poole, CIO of Sedgman, said that while the Australian resources sector previously gained market share through low-cost volume growth, costs are increasing. Countries like Mongolia and Brazil, with very low operating costs, are offering alternate supplies.

Additionally, Australian producers are no longer insulated by foreign exchange fluctuations, due to the consistently strong Australian dollar.

At the end of the day, Poole says commodity prices will fall as supply catches up with demand, and lower costs will be the key to survival.

To ensure the competitiveness of the Australian industry, Poole suggested streamlining approval processes for new projects, attracting skilled labour via policy changes – including skilled immigrations, and reforming common user infrastructures.

In terms of technologies, process improvements and improved automation and operator useability as introduced

by PlantStruxure PES will continue to help counter skills loss, lower costs and improve efficiency and safety.

Other technologies, such as the SolveIT software solution which was acquired by Schneider in August, will ease decision making by leveraging nonlinear algorithms to ensure optimal use of resources, be it workers, machinery, or transport infrastructure.

The Sconference featured a packed schedule, with a range of technical sessions, case studies and technology presentations. Case studies included presentations from the Adelaide Desalination Project, Yarra Valley Water, Tetra Pak, and Xstrata, some of which will be covered in detail by PACE in upcoming issues.

The information presented within the conference was rounded off by the marketplace which allowed attendees to explore partner technologies in their own time.

[PACE Deputy Editor Isaac Leung attended the Schneider Electric PlantStruxure NOW! 2012 Users Conference on the Gold Coast.] www.schneider-electric.com.au

NEWS

INNOVATION

PACE Awards 2013: Entries open NEXT year will be a big one as we celebrate ten years of the PACE Zenith Awards. Nominations are now open so get your submissions ready. Following on from the success of this year, this landmark 2013 awards program is set to become the biggest yet.

The annual PACE Zenith Awards was established by PACE magazine in 2004 to reward companies that demonstrate leadership in engineering, along with technological excellence and innovation. The awards evaluate projects in these industries and offers an opportunity for engineers, suppliers, integrators and industrial business-owners to be recognised publicly in front of their peers and potential customers.

The official nomination kit can be downloaded from the PACE website or by emailing editor@pacetoday.com.au Categories for the tenth annual

PACE Zenith Awards are: Automotive & Manufacturing; Food & Beverage; Oil & Gas; Machine Builder; Mining, Minerals and Exploration; Power and Energy Management; Transport, Power and Infrastructure; Water & Wastewater; Young Achiever Award; Lifetime Achievement Award; Project of the Year.

The Project of the Year Award is given out to the most innovative project overall.

Entering the PACE Zenith Awards is free. This is the only awards program specific to process, control and automation in Australia. Participating in the awards is a great way to boost your teamâ&#x20AC;&#x2122;s morale by celebrating their work and exposing it to a large audience as finalists are profiled in the magazine as well as on www.pacetoday.com.au www.pacetoday.com.au/Awards

NOVEMBER 2012 www.pacetoday.com.au 9

OPINION

ASSET MANAGEMENT

Optimise asset availability Reliability solutions offer unique a value proposition for process industries, writes Paula Hollywood.

G

LOBALLY, the process industries lose the equivalent of five percent of production annually because of unscheduled downtime and poor product quality. ARC Advisory Group estimates that almost 80 percent of these losses are preventable.

As the longest phases in any asset’s lifecycle, operation and maintenance (O&M) account for the highest costs associated with an asset. Any improvements a manufacturer can make in these lifecycle phases can have a significant impact on the bottom line.

A perfect storm. A number of factors have converged to drive the current interest in reliability software and services. Increases in the amount and complexity of plant assets employed are the primary factor, as the lines between work management and information technology (IT) become blurred.

Greater emphasis on safety, energy consumption, and environmental control compound the need for more data. Enterprises now place greater emphasis on risk management to limit their exposure to adverse events.

Add to this the growing shortage of skilled technicians to operate and maintain assets, and a “perfect storm” begins to materialise. For owner-operators, asset reliability requires the convergence of process control with work management to form the basis for a more robust approach to sustainable business performance improvement.

This convergence resolves weaknesses in one methodology, while being additive for both. For example, process control solutions cannot identify asset criticality, but reliability solutions can.

Manufacturers can improve efficiency and productivity with standardised workflows based on best practices.

Reliability solutions transform data into instantly accessible, context-appropriate information for those who need it.

Proactive maintenance as a strategy. As maintenance activities migrate from reactive to proactive, new solutions are emerging that are designed

10 www.pacetoday.com.au NOVEMBER 2012

to leverage the rich information available to manage critical issues better within the confines of operational constraints.

In terms of enterprise software for the manufacturing industries, asset reliability software is a relatively new entry to the marketplace as it applies to emerging critical issues facing manufacturers. ARC believes the real value of enterprise-level reliability software lies in its analytical capabilities.

Operational risk management.

Managing risk is an essential component of a reliability program. Decision makers need to understand the uncertainties of costs versus risks to make informed decisions about the benefits of a given strategy and any impact it may have on safety.

Identifying critical equipment; failure modes; failure effects on equipment, personnel, and the environment; and critical spares on hand enables decisionmakers to leverage the right risks, while maintaining the appropriate controls to ensure effective and efficient operations.

Visualisation capabilities in risk management modelling tools are a powerful tool that provide individuals with information in the context of their responsibilities and level of authority.

Displays of real-time information and historical trends at the management level enable actions based on facts to minimise the costs and losses associated with a business interruption.

Reliability goes mobile. Technicians frequently perform work that takes them out of range of wireless networks or handheld cradle for data transmission.

As a result, reliability solutions have migrated into handheld devices and tablets for the bidirectional exchange of data. For example, SKF offers ruggedised handhelds to support operatordriven reliability (ODR). This enables operators to take a more proactive role in initiating corrective actions for degrading equipment.

Meridium recently introduced its Tablet Application Framework, a platform that allows for the rapid develop-

ment and deployment of mobile, tabletbased applications, which integrate with Meridium’s software. Mobile applications enable access to data at the point of the asset where it is most needed.

Taking reliability to the next level.

Currently, reliability is generally an afterthought, with little reliability input in the concept and design phase of the asset lifecycle. To take reliability to the next level, it must be built into the asset.

Reliability expectations should be defined in the concept phase and used to drive reliability into the design phase of the product development cycle. Early testing can identify important failure modes that should be resolved in the final design.

Unresolved failure modes, such as normal wear of items, should be identified in diagnostic guides in condition monitoring and PAM solutions to drive appropriate maintenance strategies.

A reliable-by-design approach provides a clear understanding of the risks before products are introduced and enables end users to better address issues later, if necessary.

Historically, in the hierarchy of an enterprise, maintenance has been viewed as the ugly stepchild. It carries negative connotations; connotations that something is broken and will cost a lot to fix.

In challenging economic times, the maintenance organization is frequently the first to experience cuts in an attempt to improve profitability. Enterprises have come to the collective realisation that this attitude can be self-destructive.

As a tool in the asset performance management (APM) toolbox, reliability solutions enable enterprises to optimise asset availability and utilisation to help mitigate exposure to risk.

[Paula Hollywood (phollywood@ arcweb.com) is a Senior Analyst at ARC Advisory Group. She has been covering field instrumentation and other automation technologies for over 30 years. She currently focuses on enabling technologies and strategies for industrial asset performance management.] www.ARCweb.com

Looking for plant-wide profitability?

PlantStruxure architecture delivers

I can ensure that my production quotas meet the expected targets.

Plant Manager

I can optimise asset utilisation and reduce the plant’s environmental impact.

Engineering Manager

I can reduce engineering time to accelerate project schedules.

Energy Manager

I have visibility into the plant’s energy consumption and can finally control it.

Enhance your plant’s productivity with our collaborative process automation architecture.

Is your plant operating at its full potential? If you don’t have a collaborative architecture for monitoring and control, this question may be difficult to answer. And yet, quick access to precise information is exactly what you need to achieve optimised business performance.

PlantStruxure is a collaborative solution that allows companies to meet their automation needs whilst simultaneously addressing growing energy management requirements.

Produce effectively with PlantStruxure architecture

The integration of software, hardware, networking and communication forms the backbone of information transparency from field to enterprise.

PlantStruxure provides you with a global view across your entire plant, closing the gap between the field and enterprise, delivering real-time information to users as and when they need it.

Ensuring a safe and sustainable working environment With PlantStruxure architecture, you can finally meet your automation requirements, reduce capital and operating expenses, and optimise energy usage without lowering standards or compromising safety.

PlantStruxure – the foundation you need to yield a holistically optimised plant.

Software CitectSCADA and CitectHistorian deliver critical production related material to those who need it, while dedicated configuration software such as Unity Pro, reduces engineering and maintenance time.

Hardware From Modicon controllers to RTUs, drives and motor starters, our hardware is flexible, reliable, and highly efficient.

Networking and communication Based on Ethernet and with support for standard devices and process buses, the networks help to ensure the high availability and transparency of valuable plant data.

Learn more about PlantStruxure architecture!

Download our PlantStruxure Solutions brochure today.

Visit www.SEreply.com Key Code 52849K

©2012 Schneider Electric. All Rights Reserved. Schneider Electric and Make the most of your energy are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. www.schneider-electric.com

CLIPCOM 25447

Production Manager

NEW PRODUCTS

UniCond digital sensors Clamp-on process meter Yokogawa’s CL420 Clamp-On Process Meter is designed to make checks on DC mA lines without breaking the circuit. This instrument is a troubleshooting tool for 4-20 mA current loops on flowmeters, field instrument transmitters, signal conditioners, distributors, valve positioners and meters. The CL420’s clamp has a relatively large hole that allows proper clamping around conductors up to 6 mm in diameter and ensures stable readings with an accuracy of 0.2% up to 20 mA. The backlit dual display provides both current value and percentage of range information along with battery condition. Convenient in low light situations, the CL420 incorporates a LED torchlight and illuminated panel keys. The unit has 2 input ranges, 0-20 mA and 0-100 mA plus an analogue DC mV output for use with a DMM, recorder or data logger. Other functionality includes an auto power off feature and data-hold. The CL420 comes with a soft carrying case plus batteries. Optionally available are output cables with either banana plug or screw terminals.

Yokogawa Australia 02 8870 1100 www.tmi.yokogawa.com/au

In power plant makeup water treatment, it is possible to measure over the entire conductivity range from seawater to ultrapure water with excellent accuracy across the range, using a single model UniCond sensor. The UniCond conductivity sensor’s built-in measuring circuit eliminates errors caused by the long lead wires found on conventional sensors. Only robust digital signals are sent to its associated transmitter, which can be located up to 91m away. The UniCond sensor includes Intelligent Sensor Management (ISM) capability, which automatically communicates its sensor type, serial number and all calibration data to the transmitter when it is connected, for error-free Plug and Measure startup. UniCond sensors are used with versatile M800 and M300 ISM transmitters, available with up to four channels of measurement with full multi-parameter capability. Depending on the sensor(s) connected, these transmitters will automatically configure themselves for conductivity, pH, ORP, TOC and/or dissolved oxygen, in any combination.

Mettler Toledo 1300 659 761 www.mt.com

Monitoring process plants remotely The B4View software suite enables management and production staff to monitor the operation of their process plant or remote equipment using the browser on their laptop or desktop computer. A B4View data/web server is installed on site to collect the required data from existing PLCs or I/O devices, and then making that information available on the published web pages. Users able to connect to the server can then view the information on their favourite browser. Analogue and digital operator controls on the browser presented panel can also be transmitted back to the on site server and used as process control inputs, thus enabling complete remote control if required.

Integrated motion control package Automated Control is now distributing AMCI’s SMD23E Size 23 Integrated Stepper Motor, Drive, and Indexer package with Ethernet interface (EtherNet/IP + Modbus TCP). The SMD23E is a selfcontained motion control product with an optional encoder available for move verification. The built-in Ethernet interface simplifies connectivity to the host controller (PLC or PAC) using standard RJ45 connectors and CAT5/6 cabling. The SMD23E provides a high speed range with high torque stepper motion control. Examples of applications include conveyors, bottle capping, feeders, cut-to-length, package sorting, pick and place, and form, fill and seal. Programs use the host controller’s software. Hightorque, The NEMA frame size 23 stepper motor delivers high torque and features a 3.4 amp, DC-powered microstepping drive.

Anti-resonance circuitry ensures smooth performance and a space saving design simplifies installation and reduces wiring.

Automated Control 02 4964 4022 sales@automatedcontrol.com.au

AIE (Australian Innovative Engineering) 03 5368 7575 www.AIEglobal.com.au

Plumb-and-play chlorine dioxide analyser The CDA-22 chlorine dioxide analyser from ElectroChemical Devices is suitable for supporting raw water treatment filtration systems. Featuring a panel mounted plumb-and-play design and automatic flowcontrol, the CDA-22 is a complete chlorine dioxide (ClO2) measurement system. Treating raw water with ClO2 is an important part of the water purification process. ClO2 is used at very low concentrations (<1 ppm) in filtration systems to precipitate manganese, iron and other minerals in raw water and to break up tannins, which discolour the water often giving it a red hue. Inaccurate ClO2 monitoring may allow levels to 12 www.pacetoday.com.au NOVEMBER 2012

exceed acceptable limits, leading to the generation of toxic chlorates. Raw water sources vary in quality depending on their geographic location, the source type such as natural lake or reservoir, river or canal. Depending on many factors, the level of manganese, iron and tannins varies from source to source. Removing the manganese, iron and tannins helps clarify the water. The CDA-22 ensures that ClO2 levels are properly maintained as part of the water source filtration system, preserving safety and water quality.

Lear Siegler Australasia 02 9531 5444 www.learsiegler.com.au

IN FOCUS

Flatten regulator flow curves Operate the regulator on the flattest part of a curve where it will maintain relatively constant pressure even with significant changes in flow, writes Michael D. Adkins.

W

HEN an application calls for maintaining consistent downstream pressures at high flows, it will most likely require the use of a domeloaded pressure-reducing regulator.

Even then, you may need to add external components to the regulator to achieve your desired performance.

Your goal in doing so is to produce a reasonably flat flow curve for the regulator at a set pressure.

A flow curve for a pressure-reducing regulator illustrates the range of outlet pressures (vertical axis) the regulator will maintain based on various flow rates (horizontal axis) in a system. Ideally, you want to operate the regulator on the flattest – or most horizontal – part of a curve, which is where it will maintain relatively constant pressure even with significant changes in flow.

Unfortunately, every pressurereducing regulator flow curve will experience some droop. Figure 1 represents four flow curves, and as you read each one from left to right, the downward slope in pressure is referred to as “droop.” On the far right of each curve, you can see where pressure drops steeply.

The point from where the pressure begins to decline rapidly to where it approaches zero is called the chokedflow area. You want to avoid operating your regulator in this region because it will result in a relatively large pressure drop downstream.

This is the region where your regulator is not efficient or effective. If your flow rates will take you into this region, you should consider a different or larger size regulator.

However, when operating a regulator in the functional portion of the curve (for example, before the chokedflow area begins), you can reduce droop and achieve a flatter curve across a wider flow range by expanding the regulator’s capabilities. Using a springloaded regulator as a baseline (Figure 2), this article will explore the following system configurations:

FIGURE 1: These four flow curves represent different systems employing a springloaded regulator (curve 1) and the same domeloaded regulator with slight modifications (curves 2, 3 and 4). Each of the three domeloaded regulator systems features a different configuration designed to flatten and extend the flow curve.

The point from where the pressure begins to decline rapidly to where it approaches zero is called the choked-flow area.

R Employ an upstream pilot regulator

to control dome pressure in a domeloaded regulator (Figure 3); R Employ an upstream pilot regulator and add downstream external feedback to the domeloaded regulator (Figure 4); or R Employ an upstream pilot regulator and add downstream external feedback to the pilot regulator (rather than the domeloaded regulator) (Figure 5).

These configurations offer good, better, and best performance in terms of

maintaining more consistent pressure – and therefore flatter flow curves – over increasingly broader flow ranges.

Assumptions For this article, we’ll focus our attention on a facility that uses nitrogen from a single source for multiple processes.

Assuming that the processes are not all in continuous operation, nitrogen flow demand will vary throughout the day.

If the facility were to employ a springloaded regulator to control gas pressure, an increase in downstream flow would cause pressure drops, while a decrease in downstream flow would cause pressure spikes. Both pressure changes would require frequent manual adjustments to the regulator or additional point of use regulation.

Instead, the facility will use a domeloaded regulator, which enables dynamic pressure control – without manual adjustments – to provide more consistent pressure as flow demands vary.

FIGURE 2: A springloaded regulator, which employs a spring to control flow, provides a baseline for the flow curve comparison.

In a domeloaded regulator, a volume of pressurised gas in the regulator’s dome chamber replaces the role of the spring in a springloaded regulator (Figure 6a).

The dome chamber is pressurised at a level slightly above the required outlet pressure. This constant pressure creates a force on top of the diaphragm.

If that force is higher than the force created by the outlet pressure, the poppet will open. As pressure equalises, the downstream pressure will apply a force upward on the diaphragm to close the poppet (Figures 6b and 6c).

Figure 1 shows four flow curves for regulators that could be used in this system, each based on the same outlet set pressure of 20 bar. The first curve represents the springloaded regulator as a baseline for comparison.

The remaining three curves represent different system configurations using the same domeloaded regulator. As we’ll review, adding various external > components, and internal design NOVEMBER 2012 www.pacetoday.com.au 13

IN FOCUS

FIGURE 3: ‘Good’ – adding a pilot regulator and outlet loop to a domeloaded regulator enables dynamic control of dome pressure to enhance the domeloaded regulator’s performance.

FIGURE 4: ‘Better’ – employing a tubing run to deliver downstream pressure feedback to the sensing area of the domeloaded regulator allows this system to compensate for downstream pressure drops.

changes, to the domeloaded regulator enables pressure in the dome to be adjusted dynamically to improve the regulator’s performance capabilities.

‘Good’ domeloaded regulator In what we’re calling the “good” regulator configuration, we’ll employ a domeloaded regulator that responds to pressure fluctuations by enabling pressure in the regulator’s dome chamber to remain constant over a wider system flow range.

To allow this, we’ll add a pilot regulator to deliver pressurised gas to the domeloaded regulator’s dome chamber, as well as an outlet loop to relieve excess dome pressure (Figure 3). This setup provides dynamic dome pressure control to help the domeloaded regulator maintain its initial set pressure.

The pilot regulator’s gas source originates from the system media (nitrogen) itself. Connected with the outlet pressure through the bleed line, the pressure inside the dome will stay constant at 20 bar.

When the downstream pressure drops below 20 bar, the dome pressure will also drop; the pilot regulator will then compensate by increasing the dome pressure to the initial set pressure.

When downstream pressure rises, the domeloaded regulator will compensate by closing its orifice. This will cause the 14 www.pacetoday.com.au NOVEMBER 2012

FIGURE 5: ‘Best’ – a tubing run in this system configuration delivers downstream pressure feedback to the pilot regulator, enabling the domeloaded regulator to compensate by changing its outlet pressure. The result is a very flat flow curve over a very broad flow range.

High-flow applications typically require the use of regulators with very flat flow curves over broad flow ranges. dome pressure to increase, which, in turn, will reduce the orifice of the pilot regulator and bleed the excess dome pressure into the downstream process line. These actions bring both regulators back to the initial set pressure.

The second flow curve in Figure 1 illustrates the extended capabilities the domeloaded and pilot regulator configuration enables compared to the system using a springloaded regulator (curve 1). The set spring in a springloaded regulator loses force when it gets longer when pushing the poppet open.

This causes the droop (drop in outlet pressure). With dynamic dome

pressure control provided by the pilot regulator, the useable area of the flow curve is greater compared to the springloaded regulator.

Depending on the specifics of the application, the “good” configuration will allow for use on systems with increased flow without worry of experiencing significant outlet pressure drops.

But, we can do better.

‘Better’ domeloaded regulator In our second – or “better” – configuration, we’ll add a feedback line to enable the domeloaded regulator to compensate for downstream pressure drops. Using the same pilot regulator and outlet loop setup as above, we’ll incorporate a downstream tubing run that delivers external feedback to the sensing area of the domeloaded regulator (Figure 4).

This configuration flattens the curve.

On the downstream side of our system, pressure will drop slightly (commonly referred to as “recovery”) > after the system media exits the

NOVEMBER 2012 www.pacetoday.com.au 15

IN FOCUS

6a

6b

6c

FIGURE 6: Inside a springloaded regulator (6a), a spring applies force (Fs) to a diaphragm to open and close the regulator’s poppet. In a domeloaded regulator (6b and 6c), pressurised gas in a dome chamber replaces the role of the spring, providing force (Fd). For example, with no downstream flow demand, the poppet remains closed (6b). As flow is initiated downstream, the outlet pressure drops, causing the diaphragm to open the poppet to the point at which the dome pressure force (Fd) and system pressure force (F) equalise (6c). domeloaded regulator. For example, if the outlet gas pressure was initially 20 bar, it may be only 19 bar a short distance downstream.

An external feedback line, located a short distance downstream (usually five to 10 times the distance of the tubing outside diameter) directs the lower pressure gas back to the sensing area of the domeloaded regulator.

Here, the regulator’s diaphragm detects the lower 19 bar pressure and opens the regulator’s poppet further to increase outlet pressure. As a result, the regulator responds dynamically and more accurately to the less turbulent downstream pressure rather than a static setting.

Looking at the third flow curve in Figure 1, you’ll notice that the curve is flatter for this “better” configuration.

Remember, we’re using the same domeloaded regulator, with modifications to the sensing area, set to the same outlet pressure for the second, third and fourth flow curves.

In addition, you’ll see that the operating flow rate of the regulator has expanded before reaching a choked-flow state. However, we can still do better.

‘Best’ domeloaded regulator The third system configuration – our “best” scenario – enables the pilot regulator to make highly accurate adjustments to pressure in the domeloaded 16 www.pacetoday.com.au NOVEMBER 2012

Systems that deliver downstream pressure feedback to an upstream pilot regulator typically offer the best performance. regulator’s dome chamber based on the actual downstream system pressure. Like the “better” configuration, this design employs a pilot regulator, an outlet loop to relieve excess dome pressure, and an external feedback line.

In this setup, however, the downstream tubing run delivers external feedback directly to the pilot regulator (Figure 5).

With adjustments made at the primary pressure control source – the pilot regulator – this configuration maintains very precise control of downstream pressure and yields a very flat flow curve over a very broad flow range.

Consider this example. The outlet pressure for the pilot regulator is initially set to 20 bar, which means pressure in the domeloaded regulator’s dome chamber is slightly higher. On the downstream side of the domeloaded regulator, system pressure drops to 19 bar.

This lower pressure is directed back to the pilot regulator through

the feedback line. In response, the pilot regulator increases pressure in the dome of the domeloaded regulator, resulting in the needed correction to downstream pressure.

Both regulators – the pilot and the domeloaded – adjust dynamically to enable pressure at the downstream feedback loop to maintain the desired 20 bar. This system configuration creates a loop that enables constant, automatic adjustments to stabilise the system at the desired set pressure for optimum performance.

The results are evident in the fourth flow curve in Figure 1, which is very flat – with almost no droop – over an extremely broad flow range. This system will not experience choked flow until flow climbs even higher.

The only way to produce an even flatter – almost perfectly flat – flow curve is to replace the manual pilot regulator in this configuration with an electronically-controlled pilot regulator.

An electronic sensor attached to the regulator would make multiple pressure adjustments per second, yielding an extremely flat flow curve.

However, electronic controls are often not desirable due to power requirements and safety considerations. A system employing a manual pilot regulator with feedback directly to the pilot regulator provides very similar results without the added electronic compo-

nents, wiring, and power source.

High-flow applications typically require the use of regulators with very flat flow curves over broad flow ranges.

Variety of components At times, a simple domeloaded regulator will deliver the required parameters for an application.

However, it may be necessary to add a variety of components to a system to expand the capabilities of the regulator.

Systems that deliver downstream pressure feedback to an upstream pilot regulator typically offer the best performance.

While one can never achieve the ideal of a perfectly flat flow curve over an infinite flow range, it’s good to know there are ways to enhance a domeloaded regulator’s capabilities to realise very flat flow curves over very broad flow ranges.

[Michael D. Adkins (Michael.

Adkins@swagelok.com) is Manager, Field Engineering and Pressure Regulators, Swagelok Company. Adkins joined Swagelok in 1994. In his current role he oversees the Swagelok field engineering team, engineers dedicated to providing direct technical support to customers in the field. He also manages the regulator product line for Swagelok, where he assesses market needs and develops product strategy, positioning, and pricing.]

Swagelok 08 8369 0899 www.swagelok.com.au

NEW PRODUCTS

True colour sensor The Smarteye Colorwise True Colour Sensor is designed to work as well as an instrument or spectrometer. This sensor can solve challenging colour applications at higher speeds compared with colour cameras or closely priced competitive products. The 4 Channel Monitor provides a visual confirmation of performance without having to switch channel selections or touch the sensor in any way. It provides a choice of speed versus resolution, putting the controls of the performance of the sensor in the hands of the operator. This allows for more application solutions, and removes the limits that either speed or resolution alone can offer. It also offers control over tolerance, light intensity, output configuration (NPN or PNP), timers, input configuration (edge or gate). The sensor provides a customised solution for the colour sorting, or inspection problems in packaging and production lines.

Miniature teardrop accelerometer Dytran has introduced the models 3225M36 and 3225M37, ultra miniature teardrop IEPE accelerometers designed to adhesively mount in spaces typically inaccessible to other types of accelerometers. Available with choice of 5 or 10 mV/g sensitivity, the sensors have an overall height of 5.5 millimetres and weigh 0.85 grams. Featuring a quartz shear sensing element in a lightweight titanium housing, the models 3225M36 and 3225M37 utilise a specially designed 3-56 coaxial connector, mating with a field replaceable 6m (twenty-foot) coaxial cable assembly terminating to a 10-32 plug with adhesive mounting capabilities. Units incorporate Transducer Electronic Data Sheet (TEDS; per IEEE 1451.4) for larger channel count applications.

Pryde Measurement 1800 688 211 www.pryde.com.au

Metromatics 07 3868 4255 www.metromatics.com.au

High-speed atmospheric plasma system Precision Mechatronics has launched its upgraded range of high-speed atmospheric plasma systems. This technology can be used for treating MEMS, microfluidics, semiconductors, solar cells, medical devices, sensors, plastics and composites. Since the acquisition of US-based Surfx Technologies last year, Precision Mechatronics has been working on the existing Surfx Atomflo plasma systems to improve the technology. The Atomflo range of plasma systems has undergone a re-design to improve the productâ&#x20AC;&#x2122;s usability for industry applications and features upgrades which allow users to monitor the process. The advantage of atmospheric plasmas is their ease of use, cost effectiveness, and ability to continuously treat materials of any size and shape. Furthermore, the reactive gas flows out of the plasma source and around and through complex parts, such as MEMS. The Atomflo is a particle-free plasma source, and generates significantly less particle contamination than vacuum plasmas.

Precision Mechatronics 02 8875 1200 www.premecha.com

Assess safety to work outdoors Objective criteria for relating environmental conditions to appropriate levels of outdoor physical activity is valuable in industrial situations. The US military developed the WBGT [wet bulb globe temperature] basis for their training camps, and it has since become widespread for workplaces and sports activities. The Lutron WBGT-2010SD measures WBGT values, black globe temperature, humidity, air temperature, wet bulb temperature and dew point. These values can be read on the display and logged to SD card memory. There is an audible alarm to attract attention if conditions change.

Data can be logged automatically in real time at intervals from 1 second to 3600 seconds with unlimited records, or manually by button press to 99 readings. Decisions made on activity can be backed up by factual evidence of environmental conditions at a given time.

The SD card can be transferred to a PC and data analysed and saved using a standard spread sheet program. The criteria of the WBGT Index is not simply work or donâ&#x20AC;&#x2122;t work, but depending on the value, to work with breaks or to restrict intense activity.

ECEFast 1800 811 818 www.ecefast.com.au

T-slot cylinder sensors for industrial environments The T-slot cylinder sensors with integral M8 connector are suitable for consistent wiring. The position of the M8 connector, directly on the sensor results in space savings in the cable duct and prevents entanglement in cable loops. Typical applications are industrial environments such as packaging and handling or special purpose machinery. The sensor is simply inserted into the slot from the top. The self-locking mechanism allows one-hand mounting on the T-slot. For other

cylinder types such as trapezoidal slot, tie rod, profile or clean-line cylinders, ifm efector offers a range of adapters and mounting clamps in different sizes. The sensors in identical housing designs are available either as efector versions (PNP or NPN), or with a reed element. The response sensitivity of the sensors is 2 mT (PNP/NPN) or 2.1 mT (reed). ifm efector 1300 365 088 sales.au@ifm.com NOVEMBER 2012 www.pacetoday.com.au 17

IN FOCUS

Crack detection in turbomachines Machinery vibration monitoring requires appropriately selected and strategically located vibrational sensors for capturing the vibration, writes Amin Almasi.

U

NDERSTANDING the basic factors of the machinery vibrational behaviour goes beyond machinery dynamic modelling. It should involve deep understanding of the machinery’s dynamic behaviour during its operation and in any malfunction situation.

Machinery vibration monitoring requires appropriately selected and strategically located vibrational sensors for capturing the machinery vibration. The target of this article is to set out clearly and concisely the impacts of a cracked shaft on the machinery vibrations.

Vibration monitoring as a critical part of predictive maintenance programs assists in achieving smooth and long-term operation and has proven to be highly cost effective. The cracked rotating component diagnostics using vibration data combined with operational data is discussed. The advantages of vibration monitoring method as a powerful diagnostic tool are emphasised.

A crack initiation could be because of many mechanical or thermal reasons.

Subsequently, the crack growth could be driven by a combination of thermal and mechanical loads, particularly those causing alternate cyclic stress in the shaft.

A crack is likely to be influenced by the various mechanical stresses (particularly bending stresses), the thermal fields and by fluid pressure in the cracked area.

High thermal stresses arise in geometric transition zone for many turbomachines. Thermal fatigue is cause of many crack initiation incidences.

Some cracks originate from surface micro-cracks (this could be result of many manufacturing and operational reasons).

On the shaft surface (where the shaft or sleeve is in contact with the fluid), maximum stress could be expected because of the maximum thermal gradient and/or the maximum bending effect. Even if a shaft sleeve is used, a high stress could occur on the shaft surface.

The location of the thermal boundary zone in a shaft is critical.

18 www.pacetoday.com.au NOVEMBER 2012

VISIBLE: Examples of defects on an axial impeller.

Vibration monitoring as a critical part of predictive maintenance programs assists in achieving smooth and long-term operation and has proven to be highly cost effective.

If the thermal boundary is located above the crack, tensile stresses that develop in correspondence with the crack could facilitate its opening. If the thermal boundary is below the crack, compressive stresses arise and this force could attempt to close the crack.

The thermal stresses and bending stresses are usually responsible for the micro-crack generation, the crack initiation and the propagation of the crack. Generally, the thermal load, the bending stresses, the axial load, the mass unbalances, and the fluid pressure

entering between two crack faces can generate a stress distribution within the shaft and aid the propagation of a crack. The influence of the axial force would keep the crack open and the fluid pressure on the crack faces would act in the same way.

Crack detection A propagating crack generally produces a bow, which can be magnified by mechanical/thermal stresses and by the fluid pressure penetrating between the two crack faces.

The bow could generate high amplitude of 1× vibrations. In other words, the 1× vibration components are generated by the crack-related developing bow, as well as by the mechanical, thermal and hydraulic unbalances.

The 1× vibration component increases consistently when the unbalance is in-phase with the bow.

This situation is probably the most likely to occur, since the crack usually starts from micro-cracks where the maximum stresses are developed.

The 2× analysis is usually the most

convenient way to detect a crack. A cracked rotor presents two events at each rotation.

Any cracked-shaft formulation shows periodically-variable stiffness with a speed two-times the rotor speed.

An open crack generates 2× vibration components which could mainly be proportional to the depth of the crack, the bending moment and various loads (such as the fluid hydraulic forces).

A crack with a small depth would just generate a weak excitation of the 2× component. It could be difficult to detect a crack from an abnormal evolution of the 2× vibration component. Sometimes, the 2× component is so small that it could be masked by the noises. In such cases, a crack is only recognisable with advanced filtration methods (such as a nonlinear type “Kalman Filter” analysis).

The 2× vibration amplitude can be a highly nonlinear function of the depth. For example, in a case study, only 10 to 20 percent increase in the crack depth resulted in a more > than 60 percent increase in the 2×

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Decentralised Technology \ Drive Automation \ Services

More power?

Or more efficiency?

Why not both?

Opposites brought together: Discover why you no longer have to choose between one thing and another when you choose drive solutions from SEW-EURODRIVE. SEW’s energy saving solutions can help your plant reach its energy saving potential, all the while lowering overall production costs. SEW’s energy saving solutions are based on the proven SEW modular concept, from high efficiency AC motors coupled with highly efficient gear units, to premium efficient mechatronic drive systems. While one individual energy efficient drive component can achieve satisfactory energy balance, it’s only the optimised combinations adapted by SEW’s professional engineering team which can turn energy efficient drive components into impressive energy savers. Energy Efficient solutions from SEW-EURODRIVE. Another way SEW delivers.

1300 SEW AUS Melbourne (HQ) I Sydney I Adelaide I Perth I Brisbane I Townsville

www.sew-eurodrive.com.au

IN FOCUS

If the thermal boundary is located above the crack tensile stresses that develop in correspondence with the crack could facilitate its opening.

vibration amplitude. The 2× vibration components are also proportional to the fluid radial forces. The operation of a turbomachine far from the design point can consistently increase the hydraulic load and the 2× vibration.

The combination of crack excitations and 1× excitation generates the 3× vibration. The 3× vibration component is usually smaller than the 2× vibration amplitude. However, in some special instances the 3× vibration could be at the same order or even slightly higher compared to the 2× component.

20 www.pacetoday.com.au NOVEMBER 2012

The dynamic load, stiffness, and (particularly) damping of bearing and seal could show a high sensitivity to small differences in design, manufacturing (manufacturing details and tolerances), assembly (assembling tolerances) and operational effects (such as the degradation) so that the responses of similar turbomachines can be quite different.

A theoretical prediction of exact vibration behaviour (such as vibration amplitude) of a cracked-shaft would not be suitable for crack detection.

The trending can be the best tool for this purpose. The increases of 1×, 2× and 3× vibration measurement amplitudes from their acceptance regions (established based on the normal operating condition) can help to detect a crack. There are many other vibration indications for a crack (monitoring).

For example, vibration measurements could be useful at transient conditions (starting and run-down transients are often too fast to allow the collection of significant data).

DETAIL: An example of a crack in a turbomachine shaft.

However, high 1×, and 2× amplitudes (compared to normal levels) are the most significant symptoms of a crack. The vibration measurements could be in position(s) rather far away from the crack.

Usually, the vibration amplitudes will increase in all locations of a shaft as a result of a crack. Most often, the vibrations in various parts of a shaft could be at least 20 percent of its maximum

POWERED: An example of a complex rotor/shaft for a gas turbine. (located close to the excitation).

A case study is presented for a crack initiation and propagation in a centrifugal compressor shaft. In this turbo-compressor, the steady state 1×

and 2× vibrations were reported around 25 micron and 6 micron, respectively.

In a 10-day period, the 1× and 2× vibrations increased to 41 micron and 10 micron, respectively (around 60 to

70 percent increase). After another 10 days (totally 20 days), the 1× and 2× vibrations reached 76 micron and 17 micron respectively (around three times of the established normal operating vibrations). The machine tripped and the shaft was inspected. The high vibration was because of a propagating crack on the shaft.

Vibration monitoring is one of most effective and powerful modern condition monitoring methods. It enhances efficiency, reliability, availability, and safety of rotating machines.

It reduces production losses.

Synchronous and non-synchronous vibration studies (such as 1×, 2×, 3× and others) are used for identification of basic dynamic characteristics of rotors.

[Amin Almasi (amin.almasi@ WorleyParsons.com) is lead rotating equipment engineer at WorleyParsons Services in Brisbane. He specialises in rotating machines including centrifugal, screw and reciprocating compressors, gas and steam turbines, pumps, condition monitoring and reliability.]

NOVEMBER 2012 www.pacetoday.com.au 21

BEHIND THE SCENES

+HOSLQJ WR SXW \RX LQ &RQWURO

&RQWURO (TXLSPHQW

FP 7ULDQJXODU /(' 6WULS /LJKW 5HSODFH \RXU EXON\ Ă&#x20AC;XRUHVFHQW OLJKWV 6LPSO\ FOLS WR D ZDOO 9'& DQG 9'& SRZ HUHG $YDLODEOH LQ FRRO ZKLWH .

ORZ HQHUJ\ FRQVXPSWLRQ RI : 6.8 &6/ 3ULFH *67

Advantages of low speed d

P$ /RRS 3RZHUHG 'LVSOD\ )XOO\ SURJUDPPDEOH WR /&' ,3 UDWHG GLV SOD\ WR 9'& ORRS YROW DJH ZLWK WR P$ PHDV XULQJ UDQJH 3URJUDPPDEOH GHFLPDO SRLQW Â&#x201C; RU GLJLW PHDVXUHPHQW HUURU 6.8 &0, 3ULFH *67

T

',1 5DLO PRXQW 'XDO 9 5HOD\ (DFK 63'7 UHOD\ FDQ EH RSHUDWHG E\ 77/ 131 DQG 313 RSHQ FROOHFWRU RU WR 9'& VLJQDOV 9'& SRZHUHG HDFK UHOD\ KDV D /(' LQGLFDWRU DQG LV UDWHG DW $ 9'& $ 9$& 6.8 5/'

3ULFH *67

5+7 :0 6HQVRU WR P$ 2XW :DOO PRXQW WHPSHUDWXUH KXPLGLW\ WUDQVPLWWHU XVHV KLJKO\ DFFXUDWH DQG VWDEOH VHQ VRUV WR 9'& SRZHUHG &KDQQHO LVRODWHG ZLWK UHYHUVH SRODULW\ SURWHFWLRQ 'XFW PRXQW DQG 9 RXWSXW RSWLRQV DUH DYDLODEOH 6.8 5+7

3ULFH *67

/DEMDFN 8 /9 'DWD $FTXLVLWLRQ

/RRS 3RZHUHG 7HPS 7UDQVPLWWHU $ VLPSOH ORZ FRVW P$ RXWSXW ORRS SRZ HUHG WHPSHUDWXUH VHQVRU ZLWK PHDVXUHPHQW UDQJH IURP Â&#x192;& WR Â&#x192;& GHVLJQHG IRU PRQLWRULQJ 578 DQG 3/& FDELQHW WHPSHUDWXUHV 7\SLFDOO\ Â&#x201C; Â&#x192;& DFFX UDWH ',1 UDLO PRXQWDEOH 6.8 .7' 3ULFH *67

6WHSSHU 0RWRU 'ULYH

&RQWDFW 2FHDQ &RQWUROV 3K

ZZZ RFHDQFRQWUROV FRP DX 22 www.pacetoday.com.au NOVEMBER 2012

HE choice of drive type for ring-geared mills has been influenced by major trends in the operating environment.

These trends include increasing mill sizes, requiring drives that can supply higher power while avoiding stress to the network and mechanical equipment; rising energy costs, focusing attention on the need for energy savings; and greater awareness of the opportunities for process optimisation, which has highlighted the advantages of variable speed operation.

Taken together, these factors have boosted demand for low speed drives using synchronous motors and frequency converters.

Compact motors

Ă&#x20AC;H[LEOH , 2 GLJLWDO LQSXW GLJLWDO RXWSXW 9 ELW WR 9'& DQDORJ LQSXW

YROWDJH RXWSXWV WLPHUV FRXQWHUV DQG 86% LQWHUIDFH )UHH VRIWZDUH 6.8 /$-

3ULFH *67

$0 GLJLWDO PLFURVWHSSLQJ VWHSSHU PRWRU GULYHU ZLWK DQWL UHVRQDQFH WXQLQJ DQG VHQVRUOHVV VWDOO GHWHFWLRQ $XWRPDWLF RU FRPSXWHU GULYHQ WXQLQJ 6XLWV VWHSSHU PRWRUV XS WR $ 506 6.8 60&

3ULFH *67

Low speed drive solutions based on synchronous motors and frequency con v ring-geared mill drives, write Tatiana Ravani von Ow, Anu Tuomaala and

To meet the high torque requirements of todayâ&#x20AC;&#x2122;s large ring-geared mills, low speed drives generally use synchronous motors.

The motors are usually rated in the range 3.5 to 9 MW and operate at a nominal speed of approximately 200 rpm. Compared to the large 30 to 40 pole synchronous motors typically used in fixed speed drives, synchronous motors for variable speed operation have only 8 to 12 poles and are less expensive, more compact and lower in weight.

They are therefore easier to transport to remote locations, have a smaller footprint within the mill and can use lighter foundations than fixed speed motors. As a result, installation of variable speed motors tends to be easier.

Low speed synchronous motors with frequency converter control can generate sufficient torque to start a mill turning without needing an air clutch.

This is a major advantage of variable over fixed speed drives, because eliminating the clutch from the system reduces maintenance needs. Variable speed operation also

BENEFITS: Variable speed operation provide smooth starting avoiding the stresses imposed on the mill machinery and electrical network when a fixed speed system starts up. provides smooth starting, avoiding the stresses imposed on the mill machinery and electrical network when a fixed speed system starts up.

Less maintenance As the grinding process is not highly dynamic, low speed synchronous motors in mill drives can use brushless excitation. This eliminates wearing parts, helping to reduce maintenance, and keeps the requirement for AC/AC excitation power low.

The brushless exciter is a separate rotary transformer mounted on the motor shaft, and the motor supply, excitation control and protection are all provided by the frequency converter.

This compares favourably with the wound rotor motors sometimes used in high fixed speed solutions: these more complex motors need frequent maintenance due to wearing of the brushes and carbon

dust build-up.

Other disadvantages of wound rotor motors are that they put significant stress on the network and mechanical components during start up, and that gear reducers are needed.

As low speed synchronous motors generate high torque at low speeds, they need efficient cooling.

A TEWAC (Totally Enclosed Water to Air Cooled) enclosure is the optimal solution in dusty environments, however air cooled motors are also an option.

Low speeds mean that the motors can use self-lubricated sleeve bearings with hydraulic jacking pumps. As a result they can be operated at around 5 to 10 percent of nominal speed during starting and servicing.

The bearings are either flange mounted on the end shields of the motor or, for higher power ratings, pedestal mounted. Motors with

Intelligent Drivesystems, Worldwide Services

7KH QHZ IUHTXHQF\ LQYHUWHU 6. ( IURP 125'

drive solutions verters are quickly increasing their share of the market for Jouko Virta.

The weakest point in high speed drive solutions tends to be the gear reducer which couples the motor to the pinion. â&#x20AC;&#x2DC;integrated pedestal bearingsâ&#x20AC;&#x2122; are as easy to mount and align as those with flange mounted bearings, as they are delivered completely assembled and so no on site assembly is needed.

Low speed operation also avoids the mechanical problems that affect high speed mill drives. The weakest point in high speed drive solutions tends to be the gear reducer which couples the motor to the pinion.

This additional component increases the amount of equipment and the required maintenance, and it also decreases the reliability and efficiency of the complete mill.

In many cases low speed synchronous motors can be tailored to suit the application or customer specifications. For dual pinion mills, for example, customers often specify that the terminal boxes and cooling systems should be located centrally so that the cables and cooling water supply, if used, can be brought to a single point.

Motors for dual pinion mills can be designed to reduce the need for spares. By building the motors so that cooling units can be turned and the terminal boxes swapped from one side to the other, a single spare motor can be used to replace either the left or right motor in a dual pinion system.

Delivering flexibility The industry has been quick to adopt frequency converter solutions using low speed synchronous motors because they permit soft starting and controlled stops, while at the same time enabling the grinding process to be optimised.

The operator can easily react to

changes in ore characteristics and throughput, which is ideal for ores with varying grinding properties, and mills are able to achieve higher throughput for the same energy input. Process optimisation can also reduce variability in the output particle size and decrease utilisation and wear of grinding media.

Frequency converters with direct torque control (DTC) deliver precise and effective speed and torque control during start up and when the material is cascading. DTC can reduce wear and tear to extend gear life by up to 30 percent, helping to ensure high availability and minimise backlash.

The ring-geared mill drive solutions developed by the ABB minerals unit, for example, have a dedicated integrated mill controller, permitting smooth starts and controlled stops, reducing stress on the equipment and providing critical monitoring during the starting period to protect against frozen charges.

In dual pinion systems, torque and load sharing between motors is very accurate, improving the lifetime of the pinions.

The mill drive controller also provides service operating modes such as creeping and positioning, so the drives do not need additional equipment for maintenance purposes.

Creep mode can be used to slowly rotate the mill for visual inspections or grinding out. Fast and automatic positioning of the mill based on angle or liner reference reduces the downtime needed for changing liners.

These factors have encouraged many mill operators to upgrade from fixed to variable speed operation based on low speed synchronous motors and frequency converters. Many SAG mills already use variable speed drives, and variable speed is increasingly the preferred option for ball mills, too.

(Anu Tuomaala and Jouko Virta are with ABB Oy Motors and Generators; Tatiana Ravani von Ow is with ABB Switzerland.)

ABB Australia 1800 222 435 www.abbaustralia.com.au

Flexible s

!DDITONAL UNIVERSAL INTERFACE FOR CONNECTION OF 33) AND ")33 )NTERFACES (IPERFACE

%.$!4 3). #/3 6SS

#!./0%. AND (4, OR 44, INCREMENTAL ENCODERS

Intelligent s

)NTEGRATED 0,# FUNCTIONALITY FOR THE IMPLEMENTATION OF SIMPLE AUTOMATION APPLICATIONS OR TECHNICAL FUNCTIONS

Open s /PERATION OF ASYNCHRONOUS MOTORS s u/PEN ,OOPh AND u#LOSED ,OOPh OPERATION OF 0- SYNCHRONOUS MOTORS

Independent Drivesystems for Australian Industry The latest stage in the evolution of the NORD frequency inverter series SK 500E. The ďŹ&#x201A;exible modular system for automation.

You can ďŹ nd out all about NORD frequency inverters under www.nord.com.

-.1# #QHUDRXRSDLR 4 /SX +SC 2SNMDX 6@X #DQQHLTS 5HBSNQH@ TRSQ@KH@ /GNMD

%@W

VVV MNQC BNL @T -@SHNM@K "TRSNLDQ 2DQUHBD -.1# @T R@KDR MNQC BNL

DRIVESYSTEMS NOVEMBER 2012 www.pacetoday.com.au 23

NEW PRODUCTS

Non-contact infrared temperature sensor The PyroMini infrared pyrometer manufactured

by Calex Electronics features a miniature sensing head measuring 18 mm x 45 mm, making it suitable for mounting in tight spaces. The high ambient sensing head is capable of withstanding temperatures of up to 180°C without water or air-cooling. Manufactured from stainless steel 316 and sealed to IP65, the PyroMini sensing head is suitable for the food and pharmaceutical industry, as well as automotive manufacturing and other industrial measurement and control applications.

The PyroMini non-contact temperature sensing head utilises a low-noise interconnecting cable (available in lengths from 1m to 30m) making it resistant to interference from external electromagnetic fields and resistant to noise when used on dynamic moving machines such as on robot arms. Complementing the sensor is a large backlit touch-screen interface that displays measured temperature in digital format as well as in graphical view showing the history of the measured temperature, date and time. The touch screen also enables full configuration of the sensor by an operator which includes setting the device temperature range between -20°C and 1000°C. In alarm conditions, the entire display changes colour. When in data logging mode, the PyroMini records the temperature related data to a MicroSD card.

Heastern Industries 03 9894 1228 info@heastern.com.au www.heastern.com.au

IVAC cylinder reduces energy usage and costs Norgren has launched a range of cylinders designed to reduce energy usage and operating costs for OEMs and end users in a range of processing applications.

The IVAC (integrated valve and actuator control) is an integrated unit which combines the valve, flow controls, cushioning and sensors in a single actuator package.

IVAC is a weight and space optimised actuator, suitable for a range of bore sizes from 40mm to 80mm, featuring integrated valve and magnetically operated switches for complete actuator control. Able to be retrofitted or integrated within new systems, each unit requires only one pneumatic and one electrical connection, eliminating the need for multiple valve islands, components, tubing and accessories.

Norgren 03 9213 0800 www.norgren.com/ivac

In-line slurry density meter SCIAM Worldwide has introduced DM3, an in-line, continuous density meter for the density measurement of slurries in processing applications. The DM3 calculates density by measuring direct mass over a known volume within a flow tube. By directly calculating density rather than inferring or estimation, this technology improves the accuracy, value for money and environmental viability of sensor and mass flow systems.

Originally designed to replace obsolete technologies for the mining and dredging industries, the DM3 claims to be safer and more cost effective than hazardous nuclear techniques or inefficient auto-sampling within any slurry processing operation.

SCIAM Worldwide sales@sciamworldwide.com www.SCIAMworldwide.com

Pressure calibrator with built in electric powered pump The BetaGauge 330 is a small, lightweight calibrator that generates high vacuum to 2000 kPa using a an integral electric pump. The BetaGauge 330 has a form factor slightly larger than Martel’s BetaGauge 321 and weighs 1.1 kg. The housing is contoured to fit a technician’s hand with good balance top to bottom. The BetaGauge 330 provides ±0.035% of full scale accuracy on its internal, isolated pressure sensor. Temperature compensation on its internal sensor ensures accuracy in field applications. An external pressure module connection supports all 29 ranges of BetaPort-P pressure modules. A Pt100 RTD input is provided for temperature measurements accurate to ±0.1°C. The BetaGauge 330 also measures and simulates 4-20 mA loop current signals and can measure up to 30 VDC. Zedflo Australia 08 9302 1266 www.zedflo.com.au

ST100 Series Flow Meter delivers flexibility The ST100 Series Thermal Mass Air/Gas Flow Meter from Fluid Components International (FCI) has obtained full certification from the HART Foundation for its hardware and DD files. The ST100 Series Flow Meter was developed in response to discussions with instrument, process and plant engineers who wanted more comprehensive measurement information as well as the flexibility to adapt to future plant and process control technology they might deploy. Beyond continuously measuring, displaying and transmitting an array of parameters, the ST100 is the first thermal mass 24 www.pacetoday.com.au NOVEMBER 2012

flow meter with a migration path. In addition to the HART Communication Protocol, the ST100 is available with 4-20 mA analogue, frequency/pulse, alarm relays and additional digital bus communications including Fieldbus, Profibus and Modbus. Should a plant’s needs change over time or an upgrade be desirable, the ST100 Flow Meter adapts as necessary with a plug-in card replacement that can be changed out by plant technicians in the field.

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

BEHIND THE SCENES

Transform waste into green energy Anaerobic waste water digestion technologies respond to industry’s need to clean up the waste water it discharges and also to break free from the cost and pollution of fossil fuels, writes Mike Bambridge.

W

HILE solar power, wind power and tidal power grab the daily headlines, a vastly different green energy technology is quietly making progress.

Anaerobic waste water digestion technologies respond not only to industry’s need to clean up the waste water it discharges to the environment, but also to the need for industry to break free from the cost and pollution of fossil fuels – and the financial penalties such as carbon taxes.

Crucially for industry using them, the technologies provide reliable and predictable supplies of base load energies.

Apart from cleaning the wastewater, the greatest advantage of anaerobic wastewater treatment is the controlled, continuous production of valuable biogas (methane) that occurs during the wastewater treatment. Rather than polluting the atmosphere, this methane is fed back into industrial processes to be burned for heating and boilers.

Where a surplus of gas is collected, it can be fed to localised electricity generators that provide either on-site energy or

Modern anaerobic processes concentrate the process in environmentally harmonious closed reactors operated under ideal temperature and process control to optimise waste consumption.

direct it back into local grids to earn electricity and carbon credits. Technologies such as Global Water Engineering’s Raptor technologies can convert almost any organic residue into biogas.

Anaerobic digestion is a biological process whereby bacteria break down organic material into more basic compounds without requiring oxygen as a component of the process.

Anaerobic digestion occurred in natural environments where oxygen was absent, such as swamps, water-

logged soils, and in ground continuously covered by water, such as lakes and rivers. This natural process, with a helping hand from modern technology, is much more efficient as a waste consumer and converter than aerobic and physicochemical processes.

Modern anaerobic processes concentrate the process in environmentally harmonious closed reactors, operated under ideal temperature and process control to optimise waste consumption and, in the process, generate large quantities of methane (CH4) from the organic materials in the wastewater.

The quantities of methane produced can diminish or even completely replace the use of fossil fuels in the production

process: one ton of COD (chemical oxygen demand) digested anaerobically generates 350 Nm3 of methane, equivalent to approximately 312 litres of fuel oil, or generates about 1,300 kWh of green electricity.

Any factory with a biological waste stream or wastewater with high COD (Chemical Oxygen Demand) can use this technology to generate energy. Some companies making the investment have achieved payback within a year.

“Most typically achieve it within two years,” says Global Water Engineering CEO Jean Pierre Ombregt, whose company has been involved in more than 300 water and waste water > projects around the world.

SEPARATION: The Flotamet is a mixed reactor followed by a proprietary external dissolved biogas flotation tank.

NOVEMBER 2012 www.pacetoday.com.au 25

BEHIND THE SCENES

A wide range of organic residue types can be processed resulting in a conversion of the material to agricultural fertiliser and biogas.

One of the most recent in Australasia is the new Bluetongue Brewery in NSW, where a water recovery/green energy plant designed to target world’s bestpractice water reuse standards in the food and beverage industry has exceeded its designers’ expectations in its first year of service.

“Most industries have not realised the potential of this green energy cash cow,” says Ombregt. They have mainly been focusing on treating their effluent to meet local discharge standards at the lowest possible investment costs. By doing so, wastewater treatment installations have only generated additional operating costs and have never been seen as revenue generators.

“However, applying anaerobic wastewater treatment sheds a whole different light on the cost structure of wastewater treatment infrastructure. It can now actually become a substantial additional source of income for many factories and processing plants throughout the world, including the food, beverage and agro industry and other primary product processing facilities.

“At the same time they are doing water supplies a big favour because, on average, the removal efficiency of GWE’s anaerobic wastewater treatment installations is as high as 90 to 95 percent, bringing the organic load down to regulatory discharge standards for some types of wastewater.

“For more heavily loaded wastewaters, relatively small extra post-treatment steps can further purify the effluent, meeting even the most stringent discharge regulations for water re-use,” adds Ombregt.

GWE is introducing new generation technologies to transform waste water byproducts from an industrial disposal expense into green energy profits.

The Raptor treatment system for organic residues can convert almost any organic residue or energy crop into 26 www.pacetoday.com.au NOVEMBER 2012

ANAEROBIC: Bacteria break down organic material into more basic compounds without requiring oxygen as a component of the process. biogas, valuable electricity or heat, says GWE, which has built and commissioned more than 75 biogas utilisation plants for clients worldwide.

GWE’s Raptor technology stands for Rapid Transformation of Organic Residues. It’s a liquid-state anaerobic digestion process that consists of enhanced pre-treatment followed by multi-step biological fermentation.

A Raptor plant is a total solution, starting with logistics for handling the energy crop and ending with the production of biogas, green electricity or steam. A wide range of organic residue types can be processed, resulting in a conversion of the material to agricultural fertiliser and biogas.

Raptor technologies are applicable to such industries as: R food waste, such as market surplus, kitchen waste, off specification fruit and vegetables, and excess crops R agro-industry residues, like starch and sugar pulps, vegetable or potato waste R industrial residues, such as brewery waste (spent grain), fruit processing

waste, and paper mill sludge R energy crops, for example corn

(silage), various grasses, algae The diversity of the material to be processed means a range of different Raptor pre-treatments are available, to allow the highest possible conversion efficiency In the Raptor process, the pre-treated and blended substrate slurry is transferred into GWE’s Anamix digester that uses energy efficient and low maintenance mechanical mixing. The digester tank comes in sizes up to 12,000 m3.

Optional extras include a foam breaker fan, a scum buster system and a bottom grit trap. The digester tank is fully insulated, heated by recycling the digester content through a special heat exchanger.

Loading rates of up to 10 to 15 kg COD/m3 per day, and biogas production rates of up to 6.3 Nm3 per digester per day, can be obtained in Raptor plants, depending on the nature of the substrate.

The digestate from the digester is usually treated in a centrifuge for

removal and disposal of non-digestible solids in the form of wet sludge cake, ideal for use as an agricultural fertiliser.

Sludge cake drying and pelletising systems are available.

The liquid concentrate from the digester is added to the fresh solid waste in the slurry-making stage, or recycled to a TAR treatment, or ultimately disposed of in a conventional wastewater treatment plant.

Biogas generated in the Raptor process is desulphurised and partially dried, using GWE’s Sulphurix and Gasodrix systems, and consequently used for green power generation.

Alternatively, it can be used in a steam boiler for steam production, in which case desulphurisation and drying are typically not needed.

Raptor technologies is distributed in Australasia by CST Wastewater Solutions.

[Mike Bambridge is Managing Director, CST Wastewater Solutions.]

CST Wastewater Solutions 02 9417 3611 www.cstwastewater.com

IN FOCUS

Bridging the gap There are innovative ways for manufacturing operations to use middleware as the glue that binds management systems with the shop floor, writes Sarah Falson.

Y

OU may not be familiar with the term ‘middleware’, but the concept has been around for a while. Emerging in the 1980s when distributed client server systems became popular, middleware has been reinvented in various shapes and forms – but only recently has the concept proven its worth in the manufacturing realm.

If you use mobile applications or cloud computing in your company, you are already using a form of middleware, allowing your mobile to talk to your control system and then report the goings-on in the plant. Similarly, if you have implemented a software system to synchronise your Manufacturing Execution System (MES) and Enterprise Resource Planning (ERP) systems, you are also already using middleware.

“It is often referred to as ‘the dash in client-server’ as it provides the software layer that lies between an operating system and applications and its goal is to reduce the complexity of developing, running and managing applications,” IBM Australia and New Zealand business unit executive for Websphere, Adrian Albert, told PACE. “Middleware software supports business applications and is increasingly becoming more intelligent and enabling organisations to develop enhanced products and solutions. “IBM typically hosts workshops with clients and prospects to scope out a prospective solution that addresses a client’s particular need.”

Manufacturing operations today can be very complex and inflexible, which adds cost, lengthens delivery time and increases project risk by threatening business agility. However, as managers realise the benefits of developing visibility across their operation, more companies will turn to middleware.

Middleware for manufacturers can provide functionality such as automated decisions, service-oriented integration, business process management, information security, event processing, reporting and systems management.

It can also incorporate portal

LINKED: The Integration Gateway from Rockwell Automation, connecting manufacturing operations to the ERP system.

Middleware can provide a competitive advantage for manufacturers by creating an automated and managed system. technology used to build private and public information about employees and customers, as well as business intelligence such as real-time reporting tools. According to Oracle ANZ Fusion Middleware principle product manager, Alex Peattie, middleware can provide a competitive advantage for manufacturers by creating an automated and managed end-to-end system.

“A manufacturing organisation’s ecosystem typically consists of individual applications to manage production, supply chain execution, sales and operations, logistics and transport.

Middleware orchestrates each of these components, passing the relevant information between them to optimise the overall outcome,” Peattie told PACE. According to Peattie, middleware can be a comprehensive family of products, which allows you to adopt the solutions as you require them. “But it is imperative its components are seamlessly preintegrated to help you create, run, and manage agile and intelligent business applications,” he warns.

“Manufacturers may want to develop

mobile interfaces to existing control systems on the shop floor. Middleware integration and user interface technology could be used to enable this type of solution, enhancing control systems to provide updates, alerts and reports to a user’s mobile device.

“Middleware event management systems can allow manufacturers to handle the vast amount of sensory data that can be collected from SCADA systems. Event processing middleware can define complex patterns of events and monitor live sensors to warn of pending issues, faults, safety concerns or the general wear and tear of equipment.”

Manufacturers can either purchase out-of-the-box middleware solutions or seek the help of personalised consulting services. Since every company faces unique challenges, each middleware solution will be different. Solutions can range in price from tens to hundreds of thousands of dollars, depending on licenses and engineering services.

Importantly, many companies that sell MES or ERP can also provide a middleware solution to link the two areas.

Rockwell Automation South Pacific Information Solutions sales executive, Serena Moreno, says most traditional manufacturers run production systems in isolation, sometimes linked tightly to control. “Middleware is the glue that binds the different levels of the ISA 95 Communication Standard (global standard for info communication in an enterprise) together. It provides the ability to automate the link and write

the points of interaction that you want between the layers (for example, layer 0 to 5). Middleware helps you link everything up,” said Moreno.

“The power that can be leveraged by tightly coupling your ERP, MES and control layers translates to significant operational savings and performance improvements. The ERP layer provides business system information and the MES layer provides visibility into the shop floor through production management, materials management, quality and compliance.

“Tightly coupling these functions with the control layer provides real time information from the manufacturing plant level. Coupling these layers through middleware is the key to operational efficiencies.”

Moreno says that although packaged solutions are available, in her experience differing customer requirements make it necessary to engineer a solution. “In a vanilla middleware implementation, the majority of the functionality is outof-the box, but in our experience we have found that there will be a 20 to 30 percent customisation based on individual requirements,” he added.

IBM Australia and New Zealand 132 426 www.ibm.com/au Oracle ANZ 1300 366 386 www.oracle.com/au Rockwell Automation Australia 1800 762 593 au.rockwellautomation.com NOVEMBER 2012 www.pacetoday.com.au 27

SPOTLIGHT

7best of the

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

More economical motors Responding to the energy saving regulations for motors, Nord Drivesystems now provides IE4 systems from 0.55 to 7.5 kW in motor sizes from 80 to 100. They also supply IE3 motors up to size 180. In addition to standard IE2 models, they also provide IE2 ATEX versions in size 80 to 180. Nord has also made various additions to its gearbox program. The newly expanded family of industrial gear units now covers torques from 25,000 to 242,000 Nm. In this series, one standard housing per frame size spans the entire transmission range. The new two-stage helical bevel gear units in open or closed washdown designs can be cleaned easily. These aluminium gearboxes are available in five frame sizes with torques from 90 to 660 Nm. The SMI series of worm gear units follows the same approach.

These two gearbox series are suited for applications with demanding hygiene requirements. Nord uses a new treatment to provide aluminium surfaces with corrosion protection equal to stainless steel. SK 200E frequency inverters for distributed installation are now available with output ratings of up to 22 kW. SK 500E control cabinet inverters reach up to 90 kW. Models for up to 160 kW are under way.

NORD Drivesystems 03 9394 0500 mark.alexander@nord.com

Voltage monitoring for DeviceNet Turck’s 7/8-16UN minifast tees, splitters and in-line diagnostic devices, are designed for use in DeviceNet applications, including CAN networks and mobile equipment. Models are available in a standard option for classic DeviceNet use and a voltage monitoring version that contains an integrated circuit board to serve as a diagnostic tool. Voltage monitoring tees and splitters help troubleshoot and prevent downtime with LEDs that report normal, over-voltage and under-voltage conditions. The splitters provide parallel

wiring, which simplifies installations.

The ‘h’ configuration contains a tee connected to the main trunk line with one premoulded cable drop, providing a quick, convenient and space-saving way to add additional cabling within the cable tray. The splitters may be specified with any gender; negating the traditional male to female connection requirement.

In-line diagnostic devices may be used as gender changers to connect a male to male or female to female cordset.

TURCK Australia 1300 132566 www.turck.com.au

XTS eXtended Transport System Beckhoff’s XTS drive system (eXtended Transport System) integrates feeding, handling and assembly in a single system and enables new and customisable machine concepts. XTS combines the advantages of two drive principles: rotary and linear systems. The motor is integrated together with power electronics and displacement measurement. One or more movers – wireless, mobile carrier modules – can be moved highly dynamically at up to 4 m/s on an almost arbitrary and flexible path configuration. XTS can be used in many different ways in the most diverse industries. It is suitable for 28 www.pacetoday.com.au NOVEMBER 2012

high-speed material handling: pushing products, adapting product spacing, reducing or increasing product speed, clamping and moving products, transporting and discharging products, or manipulating products. An irregular product flow is isolated and transferred at a constant interval and constant speed to the next workstation. XTS enables more efficient machine designs for handling, feeding and assembly. XTS is a modular mechatronic system that can be configured to match the required geometries.

Beckhoff Automation 03 9912 5430 www.beckhoff.com/xts

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

G5 Lite series of low cost servos Rugged and light thermal imagers The Ti105 and TiR105 Thermal Imagers are the latest additions to Fluke’s series of lightweight and rugged imagers. The Ti105 helps plant technicians, HVAC/R professionals and electricians maintain and inspect electrical and mechanical equipment and components. With the Ti105, technicians can troubleshoot in seconds, allowing regular inspections from a safe distance. The TiR105 lets building inspection and energy audit professionals evaluate and report insulation problems, air leakage, moisture issues, or construction defects. The TiR105 documents visible proof of problems so repairs can be made, and then verifies those repairs have been made correctly. The Ti/TiR105’s features include the Fluke-patented IR-Fusion (picture in picture) technology, which helps users identify and document problem areas by overlaying a PIP infrared image over a digital image.

Omron Electronics has released the G5 Lite series of low-cost servos. Based on the G5 series, the G5 Lite servos represent a cut-down version, with a number of advanced features removed to reduce costs. G5 Lite servos accept a single phase 200V source and output between 100W to 1500W to a servo motor. Cables with moulded plugs are available for plug and play functionality. The matching servomotors have an optional holding brake, to maintain position when power is removed. The motor’s in-built encoder resolution is 20 bit, meaning 1,048,576 pulses are generated every revolution, ensuring accurate control. The drive accepts a pulse train input, for direct replacement of stepper motors. Both positioning and fixed value speed control modes are supported, along with eight inputs and three outputs, all with configurable functionality.

Omron Electronics 02 9878 6377 www.omron.com.au

Ultra low power pulse counting nodes Australian made ZigSense wireless sensor nodes has extended its product line to include two new pulse counting nodes. Models ZS24-REU-001 (2.4 GHz) and ZS09-REU-010 (900 MHz) were designed for ultra low power pulse counting metering applications. The user can select between ‘AA’ or ‘D’ Li battery sources or use an external DC supply of up to 24 Vdc to power the wireless pulse counting node. Ultra low current consumption combined with optimised sleep cycle may enable the node to be powered by a single ‘D’ Li battery for close to eight years. Up to four contact closure pulse inputs are continuously monitored in the background whilst the node is in sleep mode.

Totalised pulse counting data is transferred from remote wireless nodes to a ZigSense gateway where it is made available as Modbus holding registers.

Fluke Australia 02 8850 3333 sales@fluke.com.au

ZigSense 03 9842 7711 www.zigsense.com.au

Marking system for creating customisable MetalliCards Weidmuller, has released its first marking system for creating MetalliCards - markers in aluminium and stainless steel. Weidmuller’s PrintJet PRO printer together with its M-Print software allows users to create metal markers for labelling. Designed for use in and around the electrical cabinet and to tag cables in numerous industries, MetalliCards can be created using either aluminium or stainless steel. The aluminium tags are made from chromal-coated aluminium and are an affordable alternative for many applications. For those requiring stainless

steel tags, quality 316 grade stainless steel is available for labelling, for use in the process and chemical industries.

Users can customise MetalliCards to suit their needs. The markers have good mechanical characteristics that make them suitable for use in harsh industrial environments.

They are resistant to high temperatures, extreme changes to climate, and other external influences. The markers can be produced in both rectangular and circular shapes.

Weidmuller 02 9671 9999 info@weidmuller.com.au NOVEMBER 2012 www.pacetoday.com.au 29

CONNECTIONS

5

minutes with...

Frank Schrever, Principal Consultant, Machine Safety By Design How did you come to be in this industry?

I always thought it would be really great to be able to do back flips.

Sometimes it’s not what you know but who you know. I started my career in the scientific instrument industry working for US and European owned subsidiaries, ultimately rising to CEO of one.

In this environment you meet and develop relationships with a lot of wonderful, clever people who progress their own careers quite quickly.

One such German colleague had moved into a high position at Pilz 10 years after we had worked together in other companies.

He subsequently came to Australia to develop the business here and looked me up to help.

One thing led to another and he offered me the opportunity to establish their Australian subsidiary.

We quickly became the knowledge

leaders in safe automation industry. It was a fun journey.

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

Continuous business growth forever. This is of course, just not possible. Yet, all business plans are based on this assumption.

Is a sustainable business without growth possible? I’ll leave the readers to ponder that open ended question.

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

We still have one million employees in manufacturing in Australia, four times the number employed in mining.

Manufacturing is under stress because of the high dollar and other factors, however the talent and infrastructure is still here. If

this can be tapped and properly supported, concentrating on advanced manufacturing techniques, the future will be very bright.

What’s the greatest challenge in your job?

As always, trying to get the right balance between work and play. With all our modern tools and devices, just finding time to think and reflect without any other inputs is a challenge.

If you could be anything else, what would it be?

A world class gymnast. I always thought it would be really great to be able to do back flips, just for the hell of it.

(And not be criticised like the pollies are, for doing the same thing.) training@msbd.com.au 0418 371 659

IICA CORNER

Planning for the future We will work through the issues and prioritise key ones for the coming year, writes Brett Simpson.

EVERY organization embarks on an annual ritual that can be described by any number of different words or terms, all of which pretty well boil down to one word – planning.

This usually involves: Planning for the coming year and for the next several years to come; Planning for growth of existing and future customers, clients, properties, acquisitions; Planning for the future by looking back over historical patterns of an organization’s track record; Planning for risk management and unexpected contingencies. Plus much more.

Planning invariably involves senior management, but may include input from those down the chain of command and increasingly includes external planning experts.

30 www.pacetoday.com.au NOVEMBER 2012

Although the sophistication and complexity of the planning process varies from company to company, the underlying fundamentals are pretty well the same for all organizations.

Planning of course equally applies to the vast not-for–profit sector, within which the Institute of Instrumentation, Control and Automation (IICA) belongs. Like with the more familiar for-profit companies and businesses, there are huge differences in size, scale, complexity, stakeholders, and organizational structures within the broad notfor-profit umbrella.

The focus of this article is with not– for-profit bodies that, like the IICA, are typically boutique professional organizations of individuals and companies that share commonality with similar areas of

professional employment and interests.

Our kinds of organizations are made up of Members who are already employed in specific industry sectors.

Their availability to devote time to their professional Institutions is therefore limited. However, the most significant role that voluntary Members play is to devise, determine and set and the strategic planning and direction they want their Institute to follow. It is then the responsibility for the (usually) small number of paid professional staff to ensure that the Institution functions smoothly.

My Institute is also embarking on its own planning process. This is now well underway, with ‘homework’ being done on various fronts for our bi-annual face-to-face Federal Council Planning

meeting in Perth later in the year.

Our key objectives at the Planning meetings are usually fairly straightforward to articulate, but of course are not always so easy to achieve.

It therefore falls to those Members at the face-to-face Federal Council Planning Meetings to work through the issues and prioritise the key ones that will be the focus of attention for the coming year.

I look forward to attending the forthcoming Perth Meeting as I know it will provide much constructive discussion, debate and action oriented outcomes that will assist us all towards achieving our priorities for the benefit of our Institute.

[Brett Simpson is President IICA.] admin@iica.org.au www.iica.org.au

B2B SPECIALISTS

With 30 years experience, Mardev can provide you a list for your next direct marketing campaign.

FOR A FREE QUOTE CONTACT LEANDRO ABIZ on 02 9422 2642 or email Leandro.abiz@reedbusiness.com.au

You’ll love what we’ve done with your calibrator.

The NEW Fluke 754 lets you do the work of several tools. Calibrate temperature, pressure, voltage, current, resistance and frequency. Easily troubleshoot HART instrumentation, not to mention record and document your results.

All this plus a brighter screen, newer software, improved battery life, USB port, and improved accuracy with a 99.6 % confidence level. Fluke process calibrators: Work smarter. Work faster.

Find out more at: www.fluke.com.au Contact Fluke Australia p: +61 2 8850 3333 e: sales@flukecom.au

CO M M U N I C AT I O N F O U N DAT I O N