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

PACE.OCT12.PG001.pdf

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OCTOBER 2012 | VOL.65 NO.9

How to fix a problematic wireless local area network Do not assume the hardware is to blame if you experience poor results with your WLAN setup. It could be the installation. AD_ P ACE S CHOCT _ 1 2 . p d f

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PACE.OCT12.PG003.pdf

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CONTENTS

Published monthly by Reed Business Information Pty Ltd

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IN THIS ISSUE

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OFFICIAL MAGAZINE OF:

18 News Analysis 6

Show Preview 18

Conversation 10

Technology Report 24

Low energy robots Recent advances in robotics enables cost-effective models that deliver faster return on investment. Benefits with Thin Clients ACP’s Keith Jones spells out the many challenges and advantages for organisations moving to a Thin Client setup.

Engineer’s Update 29

GME 2012: A sneak peek A roundup of some of the innovative products that will be at the Goldfields Mining Expo in Kalgoorlie.

How to read a flow curve Once you understand a regulator flow curve it is easy and very quick to read. IICA Corner 38

Turbo-compressors demystified The importance of correct dynamic simulations and proper selection of control components should always be emphasised.

Reaching out to students We need unique initiatives to attract the next generation to careers in instrumentation and automation.

ON THE COVER P ACE . OCT 1 2 . P G0 0 1 . p d f

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PACE.OCT12.PG004.pdf

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COMMENT

EDITOR’S MESSAGE

Don’t ignore robotics Kevin Gomez Editor

Next Issue

• Test & Measurement • SCADA & MES • Motors, Drives & Motion Control • Asset Management & Maintenance

THE last article we slotted into this magazine is the one on automation (on page 6) and it touches on the reluctance of companies to invest in robotics. Our industrial landscape is dominated by small and medium scale operations and the reason to shy away from robotics is often attributed to cost. Some manufacturers do adopt a short-term approach, and there is a perception that the pay back period is longer than often is the case. Robots are rapidly getting smaller, faster more intelligent. And cheaper.

If we are to maintain some semblance of global competitiveness, our industries must take a good hard look at smart automation. Perhaps we need a noncommercial information and education campaign to demonstrate to manufacturers how they can benefit from automation. Over 2.3 million industrial robots have been sold worldwide and numbers are growing rapidly – estimates vary between 39 and 51 percent in 2011. In fact, 2011 will be remembered as the most

successful year for industrial robots since they were first adopted in 1961. Our industries need to take a good hard look at investing in automation technologies as it can bring down manufacturing costs, introduce flexibility in production and improve quality. The automotive parts industry and food & beverage sector are prime candidates. Globally, robotics is now a huge $25 billion market; a significant component is comprised of services and software. These are areas where Australia can play a part even

though we may be marginal consumers of this technology. But we have to be in the game first. Perhaps, we can learn from the British Automation & Robot Association which has commenced a series of engagement programmes. Interested companies are offered a manufacturing review where an independent expert assesses their facility, and prepares a report that identifies opportunities, if any, for automation. All this at no cost to the company. kevin.gomez@reedbusiness.com.au

TECHNOLOGY

Futurist makes bold predictions on tomorrow’s world By JIm PInTO

desktop, we’ll all have millions of chips 99 percent accurate. WELL-KnOWn futurist, Dr michio in cars, appliances, clothes. By 2020, In this augmented reality, “blink Kaku has hosted several TV specials for the word “computer” will have vanished and go online” will change everything. BBC, the Discovery Channel and the from the English language – everything Students will look up the answers to Science Channel. Kaku is Professor of will be “smart”. tests while taking them. Actors will read Theoretical Physics in the City College In his latest book, Physics of the from their scripts while performing of new york. He has written several Future, Kaku predicts driverless cars by on stage. Foreigners will translate their books about physics and has two New 2020 and synthetic organs by 2030. conversations instantly. And speechYork Times best sellers: Physics of the DnA chips inside toilets will sample makers will never need teleprompters. Impossible (2008) and Physics of the blood and urine and report Cancer, These gadgets seem decades away, Future (2011). Here are some of Kaku’s maybe 10 years before a tumour forms. but Kaku insists that they’re coming thoughts and predictions. Artificially intelligent doctors will very, very fast. The military already has Every 18 months, computer power appear on the wall when needed. The a prototype of the contact lens called doubles (moore’s Law), so in eight body will be scanned with a hand-held “Land Warrior”, a helmet with an A Da _microchip P A C Ewill M Ecost T Aonly P Ra_ 1 2 . p mRI d f machine, P a g ewhich 4 will 2 analyse 0 / 0 3the / 1 2 , eyepiece 5 : 1that 1 allows P M the wearer to see the years, penny. Instead of one chip inside a results to provide a diagnosis that is entire battlefield – friendly forces, enemy

forces, artillery, aircraft, everything, just by flicking it down right over the eyes. Propelled by advances in nanotechnology, artificial intelligence and biotech, the world will become a fully globalized civilisation by 2100. Kaku predicts that the planetary language will be English, and the Internet will be the planetary telephone system. The European Union and big trading blocs will be the planetary economy. The Olympics will be the planetary sports. And there will be planetary youth culture like rock ‘n’ roll and rap. www.jimpinto.com

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PACE.OCT12.PG006.pdf

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NEWS ANALYSIS

ROBOTICS

Technology advances shorten roI times By Sarah FalSon WITh manufacturers facing the rising cost of labour, a shortage of skilled workers and cheap competition from overseas, there is no question that operating in australian industry today is tough. however, investing in new technology to tackle these setbacks is often considered an insurmountable task. according to headland general manager, robotics and automation, Greg Sale, manufacturers need to be aware that remaining ‘traditional’ in the manufacturing realm can be detrimental to one’s business, and investing in new technology such as robotics and automation can be fruitful in the long-term. “Many small manufacturers don’t think they are big enough to automate, and this can be the beginning of the end for them. We have a responsibility to these smaller companies to help them understand how cost-effective, safe, reliable and easy-to-use good automation is,” Sale told PACE. With suppliers constantly improving their robotics and automation offerings – especially in the areas of speed and power consumption – ‘investing to save’ is the mantra many smart manufacturers are adopting. “Presently the Federal Government will even assist with the cost of replacing old, energy-hungry robots with robots that have a proven power reduction feature like Kuka’s ProFIenergy profile [distributed by headland], which reduces the robot’s energy consumption by as much as 90%,” Sale said. “Is it a good time to invest in robotics... and specifically to the manufacturers who don’t have robotics at present, those who make a lot of repeat product, or those with sound vision and business plans it’s a great time to invest in robot based automation, probably the best I have seen in over 20 years. “Don’t dismiss automation as too expensive or not right for your manufacturing. In the end you are experts in your field, and likewise so are we. Just ask. I consider that giving the right initial advice is imperative, from the benefits to the downsides, and whether automation is the right direction, or whether that skilled person is actually making you a lot of money and shouldn’t be replaced,” 6 www.pacetoday.com.au OctOber 2012

INNOVATE: Manufacturers can now utilise cost-effective robots for an everincreasing range of applications.

Sitting still will allow the competition to get further ahead and bandaid solutions will often cost more in the long run. advises Sale. robotic automation marketing officer, Peter Davis, agrees that the market’s need to reduce day-to-day manufacturing costs is a compelling reason to take the plunge. “you can’t better your production without investing in it. Sitting still will allow the competition to get further ahead and ‘bandaid solutions’ will often cost more in the long run,” he warned. “robots are becoming increasingly more efficient, and manufacturers can now utilise robots for an ever-increasing range of applications – not just in the production line, but further afield such as in warehousing and distribution. “a lot of improvement has been made in minimising the foot-print of robots while increasing the dexterity with added axes of movement.”

Davis cites a project performed by robotic automation, in which the company’s SIa20 robot allowed a CnC machine to be automatically tended without increased floor-space and without blocking operator access. “This example shows how the latest robotics can adapt to the plant without the plant having to adapt for automation,” he said. according to aBB australia general manager – robotics, olivier Coquerel, manufacturers would do well to consider robots in context of the bigger picture, rather than as a single solution. “I don’t think you should invest in robotics because robots are now a little bit cheaper or because you can get them funded by a government grant. It has to be planned and be an integral part of your manufacturing strategy,” he said. “Most of our customers have different needs. Some of them in food and beverage are facing increasing demands for their products and need robots and automation to cope with the additional volume. “others just won contracts with a mining industry and use this opportunity to upgrade their production processes with innovative solutions which will improve their bottom line

EFFICIENT: This Headland Kuka robot incorporates the PROFIenergy profile which can reduce the robot’s energy consumption by as much as 90 percent. and put them in a better position to win further businesses.” Coquerel shares the following tips for manufacturers thinking about investing: “If you work two to three shifts then there are probably some good potential projects which will offer you a short return on investment. also, if you are looking to improve productivity and reduce the material waste then you should look at robots to automate some tasks,” he said. “The best advice I can give you is: 1. work out in dollars what to try to achieve (e.g. increase my production by 20% which will give me an additional revenue of $XX; reduce my waste by 30% which will give me a saving of $XX); 2. talk to one of our experienced australian authorised Value Providers to see what solutions can be implemented to achieve your targets.” www.abb.com/robotics

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PACE.OCT12.PG008.pdf

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OPINION

AUTOMATION

Automating procedures can im pro

In demand-limited manufacturing industries the over arching objective is to improve utilisation. Plants cann ot achie

ROCEDURES govern the world of process automation. While we like to refer to the process industries as being largely â&#x20AC;&#x153;continuous,â&#x20AC;? in actuality, process manufacturing is constantly in flux. Whether you are doing a startup, shutdown, grade change, or are in the middle of a maintenance turnaround, your plant is governed by procedures and transitional states that can either run smoothly and provide you with nearly seamless grade changes or product changeovers and safe and orderly start-ups and shutdown; or they can cost you in terms of unplanned shutdowns, incidents, lost product, and lost opportunities. In demand-limited manufacturing industries, the overarching objective is to improve utilisation. Plants cannot achieve this without reducing unplanned downtime. ARC research shows that the largest reason for unscheduled downtime is operational or human error, which accounts for approximately 42 percent of the unscheduled shutdowns in the enables flawless intervention by excepprocess industries. Of that 42 percent, tion and relieves operators of manual 16 percent is directly related to procetasks, freeing time for more value added dural error. When researching the role activities. of operators in the refinery of the future, The same research also identified several major operating companies procedure automation as one of the key concluded this automation A D _ Pthat AC E can K I be N addressed O C T _ 1 2 . p process df P a g e 1system 1 1functions / 0 9 / 1 2 , through a high-level perspective that (along with alarm management and an

operational perspective) that can support this environment of flawless intervention. The expertise and operating level of experienced operators can be incorporated into automatic sequences and used to standardise operating methods and improve 1 1 : the 1 3efficiency A M of all operators. An important part ARCâ&#x20AC;&#x2122;s vision for

the collaborative process automation system (CPAS) of the 21st century is that, in developing an overall automation strategy, humans should be allowed to do what they do best and automation should be allowed to do what it does best. Humans are good at ad-hoc intervention and non-linear reasoning. They do best when empowered with an overall production cycle perspective. Machines and automation are good at repetitive functions, steady state operation, and managing transitions. Automation provides an environment for unbroken, precise execution, linear reasoning, and can consistently implement best practices through automated procedures. Today, operational procedures can be lumped into three primary categories: manual, prompted, and automated. In manual procedures, the operator performs the necessary actions required either through personal experience or by following standard operating procedure (SOP) manuals. The consistency with which manual procedures are performed can vary greatly depending upon the level of experience of those carrying out the procedures. Manual procedures also call for manual record-keeping, which can also vary in consistency and quality. Electronic records are preferable, but their quality can also vary depending

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im prove process plant performance

nts cann ot achieve this without reducing unplanned downtime, writes Dave Woll. upon the accuracy with which they were implemented in the process automaemerging ISA 106 standard, introduced entered into the system. There is no way tion system. The difference is that in 2012, is fulfilling the same role. to verify that the manual procedures automated procedures will go through This is not to say that automated followed were in fact consistent with the entire operational sequence before procedures were previously unknown in printed SOPs. Prompted operational stopping, unless either the operator or the continuous process industries. Many procedures go one step further. Here, the system intervene on an exception companies have implemented sequence the procedures are implemented in the basis. Automated procedures can further logic that allows procedures to be autoprocess automation system and the reduce transition times and variability. mated. However, these have been done operator is prompted to acknowledge Many industries have been using largely in an ad hoc framework using that each step has been successfully prompted or automated procedures for custom programming methodologies completed in order to continue. some time. The batch processing industhat can become cumbersome when it Prompted procedures make it easier tries such as food and beverages and comes time to upgrade the automation to keep electronic records and verify specialty chemicals have used the ISA-88 infrastructure. This ad hoc approach also that procedures were followed correctly. standard for years. carries a high cost of ownership, since They can also decrease both transition This defines a modular approach the procedures have to be maintained by times and product variability. to batch automation and batch procethe end user. Changes made to the code Like A D _prompted P A C E operational A M S M A proceR _ 1 2 . p dures. d f In P refining, a g e petrochemicals 1 2 2 / 0 2and / 1 2 , over 8 time : 2 9can create A M a tangled mass of dures, automated procedures are other continuous process industries, the â&#x20AC;&#x153;spaghetti codeâ&#x20AC;? that can be impossible

to translate. Many end user companies in the process industries today are also the result of mergers and acquisitions. Along with that come the many system platforms and unstructured code implementations that have accumulated over the years. Clearly, this is not a sustainable way to do business. As a result, more and more end users are standardising approaches and many have either already adopted, or are considering automating startups, shutdowns, grade changes adopting procedure automation. [Dave Woll (dwoll@arcweb.com) is vice president, ARC Advisory Group.] www.arcweb.com

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PACE.OCT12.PG010.pdf

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CONVERSATION

AUTOMATION

Big benefits with Thin Clients Keith Jones spells out the advantages of moving to a Thin Client setup. By Kevin Gomez. it will switch to the backup application and put it in front of the operator.

Keith Jones is International Sales Manager, ACP. He has been involved for over 20 years in computer systems engineering in the manufacturing arena. Currently based in California, Jones has lived and worked in the UK, Singapore and Dubai. He is tasked with supporting and developing ACP’s international channel. Jones recently spoke with PACE about the concepts and practice behind Thin Client setups.

Can you outline the key business benefits of Thin Clients? The business benefits of a Thin Client architecture come from lower capital costs for hardware, improved availability and security, and ongoing general operations costs, which using the right hardware and software architectures can be reduced by up to 70% annually. Traditionally, people have implemented automation solutions with computers everywhere – on the plant floor, in control rooms, in the administration buildings. The PCs are connected with an automation network on one side and an office network on the other. The two don’t mix. If you contrast that with a Thin Client setup, what you have at the operator station is a low cost, ruggedised, diskless, fanless unit. This unit only needs to have the user interface which communicates over the network to the application running on a server. ACP’s flagship product, ThinManager, is used to enable easy and secure management of such architectures. Using Thin Clients enables users to drastically reduce the number of PCs in their organisation and there are several good reasons to do this. PCs are an inherently weak link and have a limited life span. I like to quote the example of one of my customers who has a smelting plant. He has 50 PCs operating in a reason10 www.pacetoday.com.au OctOber 2012

ably dirty environment. Even by putting these PCs in boxes, their lifetime is about two years. Essentially, every fortnight he needs to attend to a failed PC. A team member needs to go the store and get a new one, image the disk or reinstall the OS, install the application software, configure and bring it up to date, take it to the site where the failed unit is located, and replace the unit. That’s an eight hour operation for an engineer. While they are attending to the failed PC, the process is down and has to be catered for by a manual operation. What happens if a Thin Client fails? Well, we have customers that have been running these units for 10 years. But if it does fail, an operator or an unskilled person goes and gets one out of stores. Typically, they’re much lower cost than a PC, so there’s lower inventory cost. The operator goes to the location of the failed unit, takes all of the wires out of the old unit, plugs them into the new unit and then powers up. The next thing the operator is aware of is an application that’s back in front of him after a five or 10 minute operation. While he’s handling the changeover, the process is still running because the applications are running on terminal

servers in a clean room, centrally controlled and secure. So there’s been no physical application down time, just the user interface when the operator had to have his unit changed. The other scenario concerns availability. You’ve got all of your eggs in this basket called a server - running 15, 20, 25 different applications in there. That’s no real different to the mainframe days. What happens if that server fails? Well, ThinManager is responsible for determining a series of available computing resources that the applications can run on. So should a server fail – that is running HMI for example – ThinManager determines the next best available PC and delivers it to the operator. Without the operator doing anything, he’s got his applications back again in front of him, and ThinManager has managed the failure on that side of the server. Now, if that operator was doing something crucial like pouring hot steel, you can’t afford even a few minutes of screen blankness while switching from one machine to another. ThinManager has a feature called Instant Failover – essentially the primary application and the backup application are available to the operator. If the primary system crashes, within a second

How do companies typically migrate to a Thin Client environment? There are a number of ways. It usually involves first moving applications from PCs around the plant floor to a central terminal server – installing the applications on those terminal servers and then accessing them exactly as you would with a remote desktop session. Once you’ve got the ability to do that, you’re half way there. You then need to replace the client PCs from the floor with Thin Clients. If you really need PCs there, you use something like WinTMC, which is a ThinManager Thin Client emulator for Windows. We have two pieces of software which will actually emulate a Thin Client in case you really need to have a PC, or maybe you haven’t fully amortised the cost of your hardware. You can do it in a gradual hybrid manner. How do companies future-proof their investment? The Thin Client is doing a very simple task – it’s taking graphic information from the server and displaying that on its screen or screens and it’s taking keyboard input back. We’ve got installations that are still running with 486-based Thin Clients. The Thin Client is not a big quad core, multi-gigabyte computing beast. Single core is fine; dual core is only needed if you’ve got a lot of graphics processing or multiple screens. Half a gigabyte of memory is all it requires. The future-proofing comes from the way the Thin Client is architected. When a Thin Client powers up it, looks on the network for a boot server to get started. ThinManager is a boot server and sends a core image to that client. It also sends a configuration and any other pieces of software that it might need. From the future proofing perspective, we ensure you are always able to deliver the operating image version you need, especially if you’re in a validated

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metals production is a significant area for ThinManager in Australia. Globally this our fourth largest sector behind food & beverage, pharmaceuticals and packaged goods. Thin Clients have very ruggedised capabilities. Some of them can operate in temperatures up to 85 degrees – that’s a very useful feature in a mining environment. There are models with hazardous environment capabilities and can work in explosive environments. We have implementations in the Xstrata Raglan Nickel Mine, Vale, Chevron Mining and Rio Tinto Copper among others.

centralised server and is being delivered to the operator. First of all, you need to make sure that your network is in place. ThinManager will enable you to strengthen your network and have multiple backup networks. Next, make sure your applications are capable of running in a remote desktop environment. Usually that’s not a problem, certainly in automation where applications are able to run in a terminal services configuration. industry. Since the very first release, Then it’s a matter of budgeting for ThinManager has been backwards your servers. These servers are typically, compatible. Thin Clients get their two, maybe three, machines, much more instructions from the server. You future powerful than the PCs they’re replacing. proof by making sure that the applicaWhat are the challenges in impleA typical server might be able to run 15 tion management software will always be menting a Thin Client solution? or 20 HMIs. able to handle those Thin Clients. The main challenge is to make sure So you could well be replacing 15 you’ve got a network infrastructure that PCs with one server. There’s a cost Which specific industry sectors are is not going to let you down. saving there, but it is an investment. you targeting? Instead of a local PC doing all the Then, you’ve got to buy your Thin I can go_byP what weSfind an8architecAD ACE C HinOour C Tgeneral _ 1 2 . p work, d f you’re P a gmoving e 1 to 1 / 0 9 / 1 2 , Clients 1 0 :which 0 2 range A Min price from a customer demographics. Mining and ture where your application runs on a few hundred dollars to a few thousand

ThinManager is designed to manage the clients as well as the servers and is basically designed for automation rather than the office.

dollars, depending on their capabilities, environmental ruggedness, built in touch panels and so on. You need to budget for this. The good thing is you can do this in a staged process by implementing a hybrid architecture as you migrate. People sometimes question why they should purchase a $400 Thin Client when they can get a more powerful new PC for close to the same price. Well, I’ve seen people running $300, $400, $500 PCs on a plant - and they sit inside a $2000 container just to keep off the dust. You’ve got a capital expenditure on your Thin Client, but it’s usually not as dramatic as you would expect. These units will last far in excess of a typical PC’s lifetime. The mean time between failures for a Thin Client can be extremely long. [ACP is represented locally by Wonderware Australia.] www.wonderware.com.au

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BEHIND THE SCENES

Wireless Local Area Netw ork

A Queensland-based cement company sought to improve its productivity by implem to call in the experts. Do not assume your hardware is to blame if you experie nce poo

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12 www.pacetoday.com.au OctOber 2012

FIGURE 1: Showing the three unloaders in the parked position.

HANKFULLY, for one Queensland company experiencing major wireless communication problems, Siemens was able to come to the rescue and rectify the situation without the need to purchase or replace any hardware. Sunstate Cement, an Australian-owned supplier of cement products to Queensland and northern New South Wales, sought to improve its productivity through wireless communications. The company had completed work recently on an $85 million expansion program that increased capacity to 1.5 million tonnes per year of its bulk and bagged cement products. Part of that expansion included the installation of wireless LAN network between three massive ship unloaders and four corresponding access points. And that’s where the problems began. From day one of the installation, the WLAN didn’t function properly, meaning the loaders couldn’t communicate interrupt free back to the main controller. This posed huge safety and productivity issues. “These three shiploaders needed to work as a team

but without a reliable communication link, this was impossible,” said Siemens Australia PLC and Networks Product Manager Falk Hohmann. At first, Sunstate Cement thought the problem was with the Siemens equipment that had been installed. The company had paid to have installed a high quality wireless LAN network that didn’t function as expected. They had very low signal strength, even from only a couple of meters away from the WLAN access points and there were several communication drop outs between the main controller and the three ‘RTU’ PLCs which were installed on those unloaders.

First hand investigation

When contacted about the problems, Hohmann flew to the company’s site to investigate first hand. What he found was a comedy of errors. But understandably, no one at Sunstate Cement was laughing. “The first thing I found was that the installer of the system hadn’t conducted any WLAN channel planning. WLAN is a shared media, not like switched Ethernet,

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vity by implementing a wireless system in its ship unloaders. Unfortunately in failed to operate properly and they had experie nce poor results as it could be your installation, writes Jeff Salton. The installer had used omni directional antennae which can have high gain but a very small vertical lobe. FIGURE 2: There were many collisions because the traffic was not coordinated and there were so many collisions/interbetween the four WLAN access points. ferences because the traffic was not coordinated between the four WLAN access points,” he said. frequency division multiple access class room where everyone starts to talk He explained that access collision (FDMA). WLAN installations like this at the same time. could be avoided by conducting space usually show strong signal strength but AD_ P ACE S CHOCT _ 1 2 _ 3 . p d f P a g e 1 2 0 / 0 9 / 1 2 ,The3result : 3 is3 a very P Mnoisy classroom division multiple access (SDMA) or a very poor signal quality. This is like a but the so called ”signal to noise ratio”

or also called signal quality is so small that nobody could actually follow a conversation. To avoid overlaps and interferences, WLAN simulation software like Siemens Sinema E can be used to improve the communication performance even before the actual installation starts. “We also discovered that the engineer had installed a 5 GHz antennae but the network was configured for a 2.4 GHz frequency range. Also, the access points antennae were not only installed below structures, they were too low and adjacent to solid concrete walls,” he said. “So, after selecting the 5 GHz range for that network, we reallocated channels > to each of the access points and the

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OctOber 2012 www.pacetoday.com.au 13

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BEHIND THE SCENES

FIGURE 7: The antenna pattern should always be considered in order to determine the antennae opening angle. corresponding loaders.” weaker signal strength (-70 dBm or 48 Hohmann said channels available for percent) but much greater signal quality. the network ranged between 149 and “Unfortunately,” recalls Hohmann, 165 (5745 MHz - 5825 MHz) for this “we still experienced communication outdoor application. But because there drop outs. So, what else was wrong and is a 2 MHz overlap between channels, why was it only 48 percent?” Hohmann Hohmann arranged the channels in an looked to the client antennae, which adhoc order to prevent any interference were installed on each of the hoppers. as illustrated in Figures 5 and 6. “The installer had used omni direcUsing a Cisco spectrum analyser, the tional A D _ P A C E A B S J U L _ 1 2 . p d f antennae, P a g ewhich 1 can 2 have 8 / 0high 6 / 1 2 , second round of tests showed a slightly gain but a very small vertical lobe. When

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the loaders were in the parked position, it was impossible for the antennae to have line-of-sight communication due to a big difference in the height of the mounting positions,” he said. “Therefore the antenna pattern should always be considered in order to determine the antennae opening angle. In order to do so the -3 dB curve is the

most interesting section. “And we noticed that the antennae were mounted too close together. In order to use antenna diversity (which we would always recommend in industrial applications) properly in a 5 GHz radio cell, we recommended to use 20 times the wavelength as the clearance.” The wavelength of a 5 GHz electromagnetic wave is ~5.5 cm. Therefore, the resulting distance between the two access point antennae should be around 1.1m. Hohmann said the antennae were also mounted too close to the wall (around 4 cm), causing strong interference due to reflecting waves, resulting in signal cancellations. A minimum distance would be twice the wavelength (2 x 5.5 cm = 11 cm). And being located underneath a belt conveyor certainly didn’t help matters, either! Raising the antennae from its

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AM AD_ P ACE ROCOCT _ 1 2 . p d f

Pa ge

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FIGURE 8: The antenna was incorrectly located underneath a belt conveyor.

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FIGURES 5 and 6: The 2 MHz overlap between channels allowed them to arranged in an adhoc order to prevent any interference.

NOW current height of 2m to around 5m proved very worthwhile. Another ‘hidden’ issue Hohmann uncovered within the cable installation was the amount of redundant cable. “Here we found 5m of excess cable stuffed into a 1m channel. As we all know, buckled or wound up cables cause a very strong cable attenuation problem. Luckily, we were able to utilise the additional cable when the aerials were relocated away from the overhead structures

and raised higher,” said Hohmann. After making the changes, and using Siemens iPCF (rapid roaming functionality) the system is now operating as it was originally designed to. It has been running without interruption for more than 12 months without any replacement or additional hardware. Siemens 137 222 www.siemens.com.au falk.hohmann@siemens.com OctOber 2012 www.pacetoday.com.au 15 19729 APAC MidRange 100wx275h Ad_PACEOAU AW_en-AU V1.indd 1 17/09/2012 14:29

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IN FOCUS

Understanding robotic vision systems Robotics and vision sensors can now be integrated more easily than ever before making them ideal for multiple industrial applications, writes Simon Webb.

ACHINE vision systems are used to perform complex visual inspections for robotic applications, delivering precise, multi-dimensional feedback on a target part in the language robotics can recognise and use. Vision systems also provide information on what action robotic components should take to interact with the target object. Successfully employing vision in robotic applications requires comprehension of how vision systems work and knowledge of the tools specifically designed for robotic application needs. Vision sensors produce a way for machines to “see.” Whereas traditional sensors analyse and interpret data from a single point, vision sensors input an entire image. These sensors consist of a camera that snaps a picture of the part. The image is then transferred to memory, processed, analysed and compared against predetermined parameters. When the vision sensor evaluates the features of the part as compared to user-defined tolerances for each parameter, it determines whether the part passes or fails the inspection and outputs the results for the function of robot control. The controller and camera constitute the hardware elements of a vision system. The software elements include the control system, graphical user interface and image algorithms. A vision system’s set of features includes its vision tools and method of communicating data. Robot applications that can benefit from a machine vision system are arranged into several classes. The most common application involves randomly oriented parts moving along a conveyer belt in a range of different positions.

Coordinate transformation

The robot must adjust itself according to the orientation of the parts, grasp the items, and then palletise them. In this case, vision sensors supply the link between the randomly oriented part and the robot. For example, a machine 16 www.pacetoday.com.au OctOber 2012

ACTION: The vision system supplies information to allow the robots to grab a target object and move it to the next station.

The vision system supplies information to allow the robots to grab a target object and move it to the next station in a manufacturing or inspection system. vision system can be applied to control robots at a pick-and-place machine for assembling electronic circuit boards. Another common class of applications consists of robots that transfer parts from one station to the next station in a process. The vision system supplies information to allow the robots to grab a target object and move it to the next station in a manufacturing or inspection system. When a machine vision camera detects an object in its field of view, the

camera can locate it and establish the object’s x and y coordinates with respect to the upper left-hand corner of the image—the 0, 0 point. Yet, the robot functions with its own system of coordinates, centred on its own 0, 0 point, which generally does not correspond to the origin the vision system employs. To simplify communication between the vision sensor and the robot, and allow the robot to easily execute the correct action, vision systems utilise robot coordinate transformation. Through this capability, vision systems convert information regarding the location of the point of interest in the camera’s frame of reference into the robot’s coordinate system. In addition to the x and y position coordinates, machine vision systems frequently need to tell the robots the theta coordinate, 0, or the angle of rotation of a target object. The inclusion of the 0 coordinate allows robots to identify where a part is located, as well as be able to pick it up. Vision tools can report the position of the object and

how it is rotated, so the robot can adjust itself appropriately before picking up the object and completing a task. The x, y and 0 coordinates of a particular part can be ascertained using a variety of vision tools, which are part of the software components of a vision system. The precision available in these tools varies, as does the amount of time required to analyse the point of interest. For instance, edge-based tools provide the x and y coordinates for wherever an edge is found on the product. When several edge-detecting tools are combined with an analysis tool, the angle, or 0 coordinate can be determined. A more sophisticated blob tool can usually find the x, y and 0 coordinates of the centre of mass for an object — according to the two-dimensional average of all the pixel x and y positions and information about the overall shape of the part — allowing the robot to grab and pick up the object in a balanced way. Even more precise (and more timeconsuming) are pattern-matching tools, which provide information on the centre of an object, as well as how it is rotated, so the robot understands how it has to adjust to pick up the object.

Transferring data

Vision sensors communicate information to the robots in several different ways. The simplest and most costeffective method uses an ASCII string. In this method, the camera detects the x, y and 0 positions and sends them to the robot via a RS-232 serial connection or a TCP/IP Ethernet connection. The robot controller does not request the information — only receiving whatever information the camera sends, whenever the camera sends it. A remote command channel (RCC) feature allows a robot controller to instruct the camera to carry out a task, such as taking a picture or reporting information about an image. With RCC, data is also sent over a serial or Ethernet connection, though in a more controlled manner. The camera only transmits information to the robot when

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it is requested, streamlining the flow of data and increasing overall efficiency. In the third and most complex method, the Industrial Ethernet connection goes to a PLC or advanced robot controller. Like RCC, this method allows more regulated control for transferring the information from the camera. Further, it provides a better storage system for the information. The camera identifies the x, y and 0 coordinates of the target objects, and all the fragments of data are uniquely mapped to an exclusive area in memory. Now, when the robot controller requests information, it receives the data in a much more orderly fashion. In the simplest method of data transfer, operators must set up the robot SELECTIVE: Machine vision systems benefit robotic applications by allowing controller to listen to whatever data the robots to receive only the information requested. camera delivers â&#x20AC;&#x201D; and make sense of it. This can be challenging for the robotic components. With RCC, a more sophisticated method of data the camera sends it in. ever the robot wants it, and the data is transfer, the robot can request specific By utilising a PLC or advanced robot transferred in an ordered and grouped information at specific times, but it still controller, robots can request whatever AD_ P ACE ROC2 OCT _ 1 2 . p d f P a g e 1 1 3 / 0 9 / 1 2 fashion. , 1 0However, : 4 2 some A M less sophistimust interpret data from the format that information the camera knows, whencated robots are incapable of this system,

and other operators may not want to use an expensive PLC as the controller.

Interconnectivity

In early robotic applications, robot controllers and software were often exclusive to a specific company. To integrate other technology, such as a vision system, manufacturers needed to design a custom solution. Subsequently, developments on both sides have opened otherwise closed systems, allowing components to work with more solutions. In addition to more sophisticated capabilities, such as regulated control, and higher levels of computed processing, robotics and vision sensors can now be integrated more easily than ever before â&#x20AC;&#x201D; making them suitable for multiple industrial applications. [Simon Webb is Product Support Engineer, Micromax Sensors & Automation] Micromax Sensors & Automation 02 8748 2800 www.micromaxsa.com.au

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EIP_pace_half-pg_oct12.indd 1

30-Jul-12 2:15:15 PM OctOber 2012 www.pacetoday.com.au 17

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GME 2012 PrEviEw

Opportunities for industry at GME 2012 A roundup of some of the innovative products that will be at the Mining Expo in Kalgoorlie.

Goldfields Mining Expo (GME) Kalgoorlie Boulder Racecourse October 30 to November 1, 2012 FIRST held in 1984, GME is regarded as an essential opportunity for the mining sector to meet, network and conduct business. It showcases mining technology, equipment and services – from exploration through to extraction, production and mineral processing. The biennial exhibition, is organised by Reed Mining Events in conjunction with the Kalgoorlie Boulder Chamber of

VISITORS: Frontline mine workers are being encouraged to attend GME. Commerce and Industry (KBCCI). KBCCI CEO, Hugh Gallagher, said while the region is experiencing continuing challenges including

attracting and retaining quality mining personnel, transportation infrastructure constraints, increasing costs and uncertainty regarding various mining taxes,

Hydraulic Isolator relieves stored pressure Subzero Group will display the Hydraulic Isolator. The device is used to test for and relieve stored pressure in the high-pressure hydraulic systems used on mining and earthmoving equipment. Hunter Valley-based Subzero says it can be installed on any hydraulic machine to ensure the safety of maintenance personnel and provide secondary fire control via a single point of pressure release. “The stored hydraulic pressure in machine hydraulic systems is a significant risk to maintenance personnel as they are exposed to the hazards of spraying oil, at high pressure and temperature which can cause severe oil injection injuries,” says Subzero’s Jacalyn McIntosh. She said the device ensured all stored hydraulic pressure was released safely before work commenced on a machine. It has been recognised with a Mineral Council of Australia National Innovation Award for Health and Safety and has been installed on Caterpillar/Bucyrus, Hitachi, Liebherr and Komatsu equipment. Managing director, Scott Farrell, founded Subzero Group, the manufacturer and sole distributor of the Hydraulic Isolator, in 1999. The group has more than 550 employees and offers 18 www.pacetoday.com.au OctOber 2012

the general trend for its mining sector is sound. Frontline mine workers from Kalgoorlie and surrounding regions are being encouraged to attend GME. “Frontline mine personnel often play a vital role in selecting equipment, because they operate, maintain and work with it on a daily basis, and their insights and opinions are of critical interest, not only to senior mine management, but also to suppliers and service providers,” said Paul Baker, Exhibition Director with Reed Mining Events. The GME Women in Mining Day will be held on October 31, and will include special presentations and a networking event for all women in the region’s mining sector. The GME Careers and Recruitment Day will be held on November 1, and will look at job opportunities in the Goldfields region for those with the required training, skills and experience, as well as advice on how miners can develop their careers in the industry. www.goldfieldsminingexpo.com.au

Next generation ventilation fabric

a range of maintenance and engineering services to the mining industry through 10 specialised divisions. Its products include Harness Master wiring systems, Richwood products for bulk material handling and conveyor solutions as well as LockerBasket systems seen in bathhouses. Subzero Group 02 6540 9400 www.subzeroservices.com.au

David Moss Corporation will showcase its next generation ventilation fabric, Ventpro. Developed specifically for underground mines, Ventpro has been formulated to combine strength and durability with flexibility, enabling it to withstand the extreme conditions found in Australian mines. It also has a coating that protects the fabric from UV radiation and the chemical effects of light. Ventpro is available in a range of tubes and fittings catering for all site requirements. It can also be produced in specialty sizes as required, and can be easily and quickly installed and maintained. Incorporated in 1960, the company manufactures PE and PVC pipe and fittings and underground ventilation systems for the Australian and international markets, including the mining, industrial, civil utilities, government and agricultural sectors. David Moss Corporation 0408 256 450 www.davidmoss.com.au

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Advantages of digital radio technology

Digital density gauge with iPad interface

Icom will display a new radio combining digital technology, an inbuilt GPS receiver and waterproof and dustproof construction. The IDAS IC-F4263D series, based on 6.25 kHz FrequencyDivision Multiple Access (FDMA) technology, offered spectrum efficiency and had advantages in the event of infrastructure failure. “The range and clarity of digital radio is also far greater than standard analogue and added privacy is available through secure encryption,” said Steven Cooke, Icom’s communications co-ordinator.Icom will also use GME to show: Land Mobile Radio (LMR) equipment ranging from basic 16-channel handhelds to digital transceivers that can integrate with large-scale systems; Air band, marine, receiver and UHF CB products. Melbourne-based Icom (Australia) has been supplying radio communications products across Australia for

Realtime Group will release a digital density gauge with an iPad interface for measuring slurries and liquids. The DD-1000 gauge features fully digital operation, automatic gain stabilisation, low source activity and IP67 stainless steel construction. A new wristwatch dosimeter/radiation monitor will also be on display. Among other products on display will be: Moistscan – microwave moisture analyser for bulk materials such as iron ore and bauxite; Allscan – Prompt Gamma Neutron Elemental Analyser; Conveyor belt scales; Tramp metal detectors; Radiation survey monitors. Established in Mackay, Queensland, in 1992, as a coalmine service company, Realtime Group also has an office in Belmont, WA. As well as installation, commissioning, calibration and maintenance of all products supplied, the company says it is the largest industrial radiation inOAustralia. A D _service P A Cprovider E MI D CT _ 1 2 . These services include site audits

30 years. All Icom products are made in Japan and claim to offer reliability suited to the rigours of the mining industry. Icom (Australia) 03 9549 7519 www.icom.net.au

Industrial P-Series planetary gear units for low speeds and high torque SEW-Eurodrive will feature its P-Series of industrial planetary gear units. The P-Series, designed for applications where low speeds and high torques are required, is now available in 11 sizes and covers rated torques from 24 to 500 kNm. The units are designed so the gear motor is mounted directly in front of the planetary gear unit, eliminating the need for couplings, intermediate flanges and adapter flanges, which saves space and reduces costs. The company will also show its locally-assembled X-Series range of helical and bevel-helical gear units that cover a torque range of 6.8 to 475 kNm. The X-Series is designed for heavyduty applications such as mining conveyors, bucket elevators, crushers, mixers, agitators and shipping cranes. “SEW-Eurodrive industrial gear units have superb power, quality and are sturdy,” said Wayne Martin, the company’s WA sales manager. The modular concept enabled a high degree of customisation. Established in 1931 and headquartered in Germany, SEW-Eurodrive’s Australian division was established in 1982. It is based in Melbourne with offices in Perth, Adelaide, Sydney,

for regulatory compliance, radiation protection and emergency response planning, radioactive source supply and disposal, radiation survey monitor calibration, and environmental monitoring of Naturally Occurring Radioactive Material (NORM). pdf

P a g e 1 2Realtime 1 / 0 9Group / 1 2 , 08 9475 0099 www.realtimegrp.com

Midwest Valves & Controls Loading stations control chutes for the loading and discharge of material into hoppers and haulage equipment for transfer to the processing area.

Brisbane and Townsville. The company’s products are used in both surface and underground mining. “Our new heavy industrial solutions division in Melbourne, measuring 10,000 square metres, is being fitted out to assemble and service the largest drives in Australasia,” Martin said. “This investment enables us to increase local assembly, holding and servicing of products, allowing our customers to become productive much quicker than previous times.” The fit out of the facility includes cranes capable of handling 50 tonne loads and a storage capacity in excess of 3000 pallets. SEW-EURODRIVE 08 9251 4903 www.sew-eurodrive.com.au

Norgren’s range of extremely robust actuators, valves and filtration equipment provides reliable control.

Authorised reseller: Midwest Valves & Controls Ph: 02 6374 2808 | Email: mail@midwestvalves.com.au www.midwestvalves.com.au OctOber 2012 www.pacetoday.com.au 19

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NEW PRODUCTS

Remote analysis capability for portable Wireless LAN tools Fluke Networks has announced a remote analysis capability for its portable wireless LAN (WLAN) tools, making them the first to enable both real-time troubleshooting and spectrum analysis of remote wireless networks. This lets organisations with remote sites that do not need WIDS/WIPS 24/7 monitoring to resolve connectivity and interference problems, identify rogue devices and detect security violations without having to make expensive site visits. The remote analyser solution is comprised of AirMagnet WiFi Analyser PRO 10.0, AirMagnet Spectrum XT 3.5.1 and AirMagnet Series Sensors. Sensors can be deployed to remote sites and then be monitored via WiFi Analyser PRO or Spectrum XT at a control site. Fluke Networks www.flukenetworks.com

Low PIM antenna with high gain With design and manufacturing facilities in Australia, Rojone has modified their existing wide band antenna A-460D-NF to create a new low PIM antenna with high gain. This was achieved by upgrading the large cross section radiating element to incorporate Silver plated PTFE structures and a solid copper back radiator – plots are available for frequencies from 700 MHz through to 2700 MHz. Rojone designs and manufactures a number of specific products to suit the needs of current telecommunications applications. Rojone 02 9829 1555 sales@rojone.com.au

Smallest dual bent tube Coriolis mass flowmeter Flexible RFID Yokogawa’s Rotamass LR is said to system be the world’s smallest dual bent tube Coriolis mass flowmeter. The new Rotamass LR employs a dual bent tube and self-draining design. Designed to measure both liquids and gases, the effective turndown of the Rotamass LR is not less than 2000:1 for liquids and 5000:1 for gases. The mass flow measurement range spans from 10.5 g/h up to 40 kg/h, achieving a measurement accuracy of ±0.15% of reading for liquids and ±0.5% for gases. The measurement of tube temperature plays a key role in mass flow and density measurements. Normally it is more difficult to measure temperature with Coriolis flowmeters that have tubes with a smaller surface area. The Rotamass LR solves this problem by using an inline temperature sensor, ensuring exact and fast measurements in process temperatures ranging from -50°C to +150°C. The flowmeter features a gas-tight, all-stainless-steel secondary containment that can handle pressures up to 65 bar.

ifm efector developed a new RFID system especially for production and conveying. The evaluation unit is equipped with an integrated Profibus DP interface and a web server. Parameters can be set via a laptop. Due to the IP 67 protection rating and wide temperature range, the unit also meets the requirements of harsh industrial environments. The RFID evaluation unit features four antenna terminals or digital I/Os. The antenna concept enables connection of the LF and HF antennas by means of M12 connectors. Additionally, with a memory size of up to 2 Kbits, the product portfolio from ifm efector also offers HF transponders with 16 Kbits as a FRAM variant which can be rewritten an unlimited number of times. The RFID system platform is used in production for identifying tools or monitoring production steps. Further applications can be found in quality assurance, the automotive industry as well as in automation and conveying.

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

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Hygrometer sensor design increases reliability of tests The sensor design of Michell Instruments’ S8000 Remote chilled mirror hygrometer combines high-accuracy temperature control with new materials to improve reliability and avoid condensation. The relative humidity in climatic chambers will always deviate from the set point. Even in high precision chambers this deviation is typically between 1-3% RH, which can have a considerable effect on the results of many tests. A calibrated reference instrument such as a chilled-mirror hygrometer reduces this uncertainty to just 0.5% RH, but can be difficult to install and bulky, reducing the amount of usable test space within the chamber. To overcome these space 20 www.pacetoday.com.au OctOber 2012

issues, Michell Instruments has introduced their S8000 Remote chilled mirror hygrometer. The compact remote sensor head features an open cell design, removing the need for any complex heated sampling arrangements or an external pump. The improved design has an optional aluminium sensor head that provides a swift response to changes in temperature, preventing any risks of condensation occurring during rapid transitions between temperature set points. AMS Instrumentation & Calibration 03 9017 8225 sales@ams-ic.com.au

AD_PACEKELOCT_12.pdf

GSM-2

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D. ME D. OR F EE N NT SI A Y A R LW UA ,A .G TS ED L S L O TA RC INS OU Y 1x S CE DU RE

Picture: GSM-2 system for water level measurements

MEASURING DATA BY E-MAIL VIA GSM NETWORK The days when you had to run from measuring station to measuring station every day in all kinds of weather to read off the last water level or installed data logger are deﬁnitively a thing of the past. GSM-2, which is quick and easy to install, now transmits the measuring data straight to your ofﬁce by e-mail (via a GPRS Internet connection) or SMS. The heart of the measuring system is the GSM-2 DataManager software. The measuring data that is transmitted by the measuring stations is continuously read in, stored and displayed by the DataManager, so that you can permanently monitor your equipment. Performance features of the GSM-2 measuring system:

Level Sensor

- Battery-operated (low power consumption; service life of up to 10 years) - Less than 2” in diameter (fits into your standpipe; vandal-proof) - Battery and antenna integrated in the housing - Various sensor interfaces, built-in air pressure sensor - Remote device configuration (by e-mail) - Free PC software available - Automatic further processing of measuring data - Applications: water level/filling level measurements, pressure monitoring in general… More info:

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BEHIND THE SCENES

4D tech powers simulation training A state-of-the-art simulation training facility recently launched in South Melbourne is set to revolutionise skills training in the building and construction industry, writes Hartley Henderson.

HE Master Builders Twelve site sheds and a control room Association of Victoria’s $14 A virtual construction site have also been constructed as part of million Building Leadership the training complex. is created through the use Simulation Centre (BLSC) Participants are able to confront the in South Melbourne is only the third challenges of a real building site, but of 4D technology that facility in the world to provide simulawith the advantages of a risk-free envienables seamless images to tion training. The Centre, which is ronment. supported by an additional $1.9 million Peter Birnbaum, managing director be projected onto a huge in Federal Government funding, focuses of the Pullman Learning Group, which parabolic screen. on communication, leadership and supplied and installed the technology for problem solving. the BLSC, explains that 50,000 photos It is aimed at upskilling experienced were taken over a two year period at workers, such as project managers, two actual construction sites in the UK as well as addressing the 50 percent A virtual construction site is created (a housing development and a high-rise apprentice attrition rate by providing at the BLSC through the use of 4D office block) to create time slices of international best practice training for technology that enables seamless images construction progress on each project. theAnext generation of building and to be projected onto a huge parabolic D_ P ACE V AI OCT _ 1 2 . p d f Pa ge 1 1 4 / 0 9 / 1 2 , 4“These : 3 5photos P Mwere then rendered construction apprentices. screen in the Simulation Centre. to show various stages of construction

by utilising four high-end computers with CAD–based anti-lasing software for imaging. Three high-end projectors are used to project 5 Gigabytes of graphics onto a 15 metres long parabolic (curved) screen to create 4D graphics as a background for the training,” he said. “The anti-aliasing software enables blending of the images so that a completely seamless high quality continuous image of the virtual construction site is presented on the screen. “When the original photos were taken at the actual construction sites action was also taken to install sound devices at appropriate locations around the site, as well as on selected site vehicles, to enhance the reality of the virtual

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22 www.pacetoday.com.au OctOber 2012

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“Trainees in the site sheds learn to prioritise issues, arrive at solutions, and become aware of the impact that action or inaction can have on a construction site. “Cameras and microphones in each shed relay the activities to four touch screen computers in a central control room where the action is monitored.”

Powerful training

DIMENSION: Around 50,000 photos taken over a two year period at two actual construction sites were used to create time slices of construction progress on each project.

tion to any building defects. “This cutting edge approach to training presents challenging real life situations, and the behaviour of participants in the site sheds can be continuously observed via the cameras in the site sheds. “Feedback to participants is a critical part of the simulation training process. All site sheds are also equipped with phones that are patched into the central control room so that observers can interact with students. “At the end of each session feedback is provided so that the strengths of participants can be recognised and further developed, while weaknesses can also be identified and corrective assistance provided.”

According to the BLSC’s assistant manager, Chris Kulesza, the Simulation Centre provides a powerful realistic training experience that enables participants to develop their skills while managing a virtual site. “Trainees quickly forget that they are in a simulation situation. They are taken out of their comfort zone and quickly become immersed in the challenges Building Leadership Simulation Centre presented in managing the virtual site,” 03 9411 8000 he said. www.blsc.com.au “The main focus of the BLSC is on honing and fine tuning ‘soft’ skills such Pullman Learning Group as managing industrial relations, OH&S, and Acontractors, as well as dealing with D_ PACEPCAJ UN_ 1 2 . p d f P a g e 1 1 503/ 9557 0 5 6008 / 1 2 , www.pullmangroup.com.au customer complaints including in rela-

TRAINING: Participants walk through the virtual construction site and observe various aspects of the project up close before entering the site sheds to deal with specific issues. site at the BLSC in South Melbourne. “In the Simulation Centre, a joystick connected to a computer enables training participants to walk through the virtual construction site and observe various aspects of the project up close before entering the site sheds to deal with specific issues relating to the virtual site.” Birnbaum says these site sheds are just like any that one would find on

most construction sites and include hard copies of plans hanging on plan racks and other documentation that relate directly to the site viewed by participants in the Simulation Centre. “Participants are fully equipped with protective gear and professional actors play the roles of real people on the site, including a union official and a safety inspector,” he said. OctOber 2012 www.pacetoday.com.au 23

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Turbo-compressors demystified The importance of correct and timely dynamic simulations and proper selection of all control components should always be emphasised, writes Amin Almasi.

HE importance of correct selection of turbo-compressor system control elements (such as the anti-surge valve selection, valve opening and closing times and others) should always be emphasised. The dynamic simulation should be employed as a tool to achieve the optimum sizing and selection for control components and parameters in each stage of the project. In other words, dynamic simulations should be performed at different stages from basic design, to detailed design, final verification, and during operation. Usually in early stages of a project, some assumptions should be made for the first dynamic simulation. While these assumptions should be on a correct basis, they may not be the best options for the final turbocompressor arrangement. The design should not be limited to those initial assumptions. Figure 1 shows an example of a modern centrifugal compressor. In case of a “surge” the whole rotor system will vibrate axially which could damage the axial bearings or the seals. An axial bearing (a thrust bearing) is shown in Figure 2.

Control element selection

The origin of many parameters particularly control valve or on/off valve opening/closing times are initial assumptions made in an early stage of design. This is done to complete the first dynamic simulation for finalisation of some critical issues such as the anti-surge valve sizing, the hot-gas-bypass requirements, the basic anti-surge arrangements. In a case study for a centrifugal compressor, for the dynamic simulation at the basic design stage, an assumption was made to use 0.8 second per 25 mm of valve sizes for opening and closing time for all suction/discharge valves. This was at the early stage of the project and valve data was not available at that time. This assumption could reflect the maximum actuation time that may be expected for some large on/off valves (ordinary on/off actuated valves can 24 www.pacetoday.com.au OctOber 2012

FIGURE 1: An example of a modern centrifugal compressor.

To accurately predict the dynamic behaviour of turbo-compressor systems the model has to be supplemented with accurate input data.

achieve around 0.5-0.8 second per 25 mm). These assumptions were used for the basic design dynamic simulation which resulted in the anti-surge arrangement freeze, anti-surge valve sizes and anti-surge valve opening/closing time (in this case 2 second opening time and 4 second closing time). However, the engineering contractor used basic design dynamic simulation assumptions as a basis for specifying

all actuated valves in the suction and discharge. The engineering contractor hence specified 0.75-0.85 second per 25 mm for all main suction/discharge valves opening/closing time, considering if initial assumptions of the first dynamic simulation kept within certain limits, the first dynamic simulation could remain valid and there is no need for other dynamic simulations. This is a poor design decision. The specified values (0.75-0.85 second per 25 mm for opening/closing time) may not be wrong based on the initially assumed timing value (0.8 second per 25 mm), but there could be some difficulties to supply or verify actuated valves with such tight actuation timing and also the final result could be a sub-optimum arrangement. Optimum valve characteristics should be obtained based on a new dynamic simulation. In this case, the second dynamic simulation is performed

(considering the anti-surge arrangement, anti-surge valve sizing and anti-surge valve opening/closing time as final) and optimum reaction times are obtained as 0.71 and 0.64 second opening/closing time per 25 mm for the suction valve and the discharge valve, respectively. To accurately and reliably predict the dynamic behaviour of turbo-compressor systems, the dynamic model has to be supplemented with accurate input data based on as-built equipment performance. For example, volume of various vessels and piping systems should be accurately modelled based on fabricated (or isolated) pieces of equipment. The controllers used in the dynamic simulation models are often simplified based on basic control strategies. In this way, the simulated control systems do not represent the functionality of actual field controllers, which could have an effect on the results of the dynamic simulation. A recommended solution for inaccuracy of simulated controllers could be using a “direct control-hardware linked simulation” approach instead of conventional software emulation. This method can guarantee the simulation accuracy and the functionality of fieldinstalled controllers. During the dynamic study, an integrated software-hardware solution should be developed by linking a rigorous plant dynamic model to a vendor supplied controller emulator (based on the actual vendor controller). The requirement should be discussed with the compressor vendor (or the supplier of the anti-surge system) in the bidding stage, before the order placement. Once a dynamic model is developed, it should be validated against the design and the actual operating data to ensure the accuracy of the modelling.

Valve selection

Anti-surge valve requirements depend to a large degree on the turbo-compressor details, and the turbo-compressor system arrangement. The different aspects of the anti-surge valve sizing and selection are described. Figure 3 shows an

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FIGURE 2: An example of a thrust or axial bearing. example of an anti-surge valve. The larger the anti-surge valve, the more flow that can be moved from the discharge side of the turbocompressor to the suction side. The speed of valve opening is also important for a turbo-compressor antisurge application. Generally, the larger the valve, the slower its opening time. Also, the larger the valve, the poorer its controllability at a partial recycle. The situation could be improved by using a large valve that is boosted to open, thus combining a high opening speed with a high-flow capability. An optimum anti-surge valve should be selected for any turbo-compressor. In a case study for a turbo-compressor, two antisurge valves with the same opening time (around 1 second) were evaluated. The small anti-surge valve resulted in the shutdown surge at a moderately high pressure. The large anti-surge valve (with around two times the Cv compared to the small one) resulted in a major reduction in the head. The shutdown surge occurred at a pressure just above the suction pressure. Cv is the valve flow coefficient. Most information required for the sizing of the antisurge valve is available on the turbo-compressor map. Commonly used margins are that the anti-surge valve should be capable of passing 100 percent of the surge flow-rate at around 50 percent of the valve opening. In other words, the anti-surge valve Cv is selected from approximate range of two times of the required Cv based on the surge flow on the curve of the highest turbo-compressor speed (on the turbo-compressor map). Other requirements of anti-surge control valves are: o Reduction of the stroke time.

o A stable response. o Minimised overshooting during valve adjustment steps.

Too fast a response could result in an excessive overshoot and a poor accuracy. However, too slow a response may result in sluggish opening of the anti-surge valve. Correct size and configuration of the required actuators, instrumentations and accessories could guarantee an anti-surge valve response time of less than 2 seconds (to fully open). For a large anti-surge valve, the anticipated noise level (before an external attenuation) should never exceed 100-110 dBA with fluid velocities below 0.3 Mach. The inline and symmetrical flow path eliminates indirect flows and unnecessary changes in flow directions through an anti-surge valve. An axial-flow antisurge valve is a well-known option. The “breaker vanes” are often used in the downstream section of the valve body, which cut and streamline any flow turbulence (significant reductions in the noise, the turbulence, and the vibration). High range-ability (the ratio between the rated Cv with completely open valve and the minimum Cv that the valve can control) is required (typical range-ability “150:1”), which means a successful control even with a high ΔP and a low flow. To increase the range-ability, special trims should be used. In order to obtain service reliability, following considerations should be respected: o Anti-surge valves usually fitted with pressure balanced pistons (the thrust should be independent of differential pressure across the valve). o Bushings are anti-seize and self-lubricated. > o Proper packing should be used. OctOber 2012 www.pacetoday.com.au 25

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MM2002_PRODUCT_SUBS.pdf

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Terms & Conditions Your subscription may be tax deductible, ask your accountant. ABN 80 132 719 861. Please note RBI has a no refund policy, contact Customer Service for details on 130 360 126. *Based on previous $99 annual subscription price. All prices are quoted in Australian Dollars and GST inclusive. We are committed to handling your personal information in accordance with the Privacy Act www.reedbusiness.com.au/privacy.asp

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FIGURE 3: An example of an anti-surge valve. FP )ODW /(' &DELQHW /LJKWV o The trim materials are carefully chosen. The material

should be corrosion-proof and erosion-proof. Proper stainless steel alloys for usual services, or sintered tungsten carbides for special cases are specified. Rapid changes in the differential pressure across the anti-surge valve should have no effect on the stability of the valve position. In modern designs, the sealing is achieved usually by the position (and not by the torque). Leakages across the anti-surge valve will influence the efficiency of any turbo-compressor system. In a case study for a medium size high pressure centrifugal compressor, with an 8â&#x20AC;? class 900# anti-surge valve and 70 bar differential pressure, the valve leaked approximately 150 Nm3/h of the process gas. A typical â&#x20AC;&#x153;one anti-surge valve, one turbocompressor casingâ&#x20AC;? arrangement is always recommended. More complex systems of cascaded valves or valves around multiple compressors require a more detailed analysis and complex provisions. Generally two types of anti-surge valves are used: o Globe valve. o Noise-attenuating ball valve. The globe valveâ&#x20AC;&#x2122;s capacity (Cv) approximately varies with the square of the percentage travel. The noiseattenuating ball valveâ&#x20AC;&#x2122;s capacity (Cv) varies roughly with the cube of the percentage travel:

o Cv~(travel)2 for a globe valve o Cv~(travel)3 for a ball valve

The noise-attenuating ball valve will have more capacity to depressurise the discharge volume compared to the globe valve with the same size. In a case study for a 150 mm (6â&#x20AC;?) size anti-surge valve, the Cv of a selected ball valve was more than 2.5 times of the Cv of selected globe valve (the same size). At 2/3 of valve travel, the selected ball valve flow was more than 50 percent higher than the same size globe valve flow. This additional flow capacity sometimes makes the noise-attenuating ball valve theoretically a better choice in an anti-surge installation (it is only a theoretical and textbook priority).On the other hand, the globe valve behaviour is more predictable and more control-able (less nonlinear). A ball valve usually offers a highlynonlinear behaviour (Cv~(travel)3). Both globe valve and ball valve are used in modern anti-surge systems. Practically the globe valve is more common in turbo-compressor anti-surge systems. [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.]

5HSODFH \RXU EXON\ Ă&#x20AC;XRUHVHQW OLJKWV ZLWK WKHVH KLJK LQWHQVLW\ /(' VWULS OLJKWV 2QO\ PP WKLFN WKH\ VLPSO\ FOLS WR D ZDOO 9'& RU 9'& SRZHUHG $OVR DYDLODEOH LQ DQG FP OHQJWKV ZKLFK FDQ EH HDVLO\ H[WHQGHG 6.8 &6/ 3ULFH *67

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&RQWDFW 2FHDQ &RQWUROV 3K ZZZ RFHDQFRQWUROV FRP DX OctOber 2012 www.pacetoday.com.au 27

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PACE.OCT12.PG028.pdf

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NEW PRODUCTS

Total organic carbon sensor with ISM Range of measurement terminals extended Measurement applications with demanding requirements for accuracy and dynamics can now be seamlessly integrated into a standard control system with new EtherCAT Terminals from Beckhoff. These new terminals handle measurements for temperature or weighing. The 4-channel EL3314-0010 thermocouple input terminal, for example, meets all requirements for high-precision temperature measurement. Also, the new EL3356-0010 is an analogue input terminal for direct connection to a resistor bridge or load cell. With the EL3314-0010 EtherCAT Terminal, Beckhoff extends its range of measurement terminals. This dynamic terminal integrates temperature measurement into the standard automation system so that a dedicated and separate measurement system is no longer required. The analogue input terminal enables direct connection of four thermocouples. Compared with the previous EL3314, the measuring accuracy of the new EL3314-0010 has more than doubled. For sensor type K this equates to ± 4.11° for the EL3314 and ± 1.8° for the EL3314-0010. The terminal circuit can operate thermocouple sensors in a 2-wire system. A microprocessor implements linearisation over the whole, freely selectable temperature range. Cold junction compensation is dealt with via internal, high-precision temperature measurement in the terminals. Beckhoff Automation 03 9912 5430 www.beckhoff.com.au

Mettler Toledo Process Analytics Division has introduced the Thornton 5000TOCi sensor with Intelligent Sensor Management (ISM) for continuous, fast, and reliable monitoring of total organic carbon (TOC) levels in applications such as Water for Injection, reverse osmosis membranes, effectiveness of TOC destruct UV lamps, resin bed performance, organics shedding, and quality of final rinse water. With fast response continuous on-line measurements, the 5000TOCi sensor ensures TOC excursions will not be missed. The 5000TOCi sensor is developed specifically to meet the demands for pure water in the pharmaceutical, power generation and microelectronics industries. The 5000TOCi may be coupled with Thornton’s M800 ISM transmitter, available in two- or four-channel versions, capable of operating any combination of up to two or four sensors for conductivity, pH, ORP, dissolved ozone or dissolved oxygen, plus two pulsed flow sensors.

Gateway delivers extended communication Turck’s BL67 Ethernet gateway for Ethernet/IP and Modbus TCP/IP is designed to provide a reliable communication solution for on-machine, modular I/O applications. The BL67 is suitable for use in environments where conditions may not be conducive to traditional I/O. The BL67 satisfies applications requiring digital or analogue inputs and outputs, specialty I/O such as SSI and RFID and serial inputs to Industrial Ethernet networks. Featuring Turck’s Multiprotocol technology, the BL67 gateway combines multiple Ethernet protocols in a single device, yet only allows one Ethernet master to control the outputs while the input and diagnostic data is available to the other protocols.

METTLER TOLEDO 1300 659 761 www.mt.com/toc

TURCK Australia 1300 132566 www.turck.com.au

SIL 2-Rated SRM Safety Relay Module The SRM Safety Relay Module is a relay repeater module that has been certified by exida for single use in Safety Instrumented Systems up to SIL 2. The SRM is part of the Moore Industries’ FS Functional Safety Series and accepts single contact closure inputs from logic solver trip outputs including Moore Industries’ STA Safety Trip Alarm and the SPA2 Programmable Limit Alarm Trip. With three contacts per alarm input, the SRM allows for the addition of alarm contacts to safety processes without special installation or configuration. The SRM is a Force Guided Relay, avoiding the possibility of having contacts become stuck in both Normally Open (NO) and Normally Closed (NC) positions at the same time. Moore Industries-Pacific 02 8536 7200 sales@mooreind.com.au

Turbidity analyser with intelligent sensor The Triton TR8 Turbidity Analyser from Electro-Chemical Devices can monitor turbidity in filter backwashing systems to optimise plant efficiency. The Triton TR8 Clear Water Sensor is suitable for all phases of drinking water processing including filter backwash. It operates over wide measurement range with output available in multiple units: 0.000 to 9999 FNU, or 0.00 to 3000 ppm, or 0 to 20 percent. The TR8 TA sensor features an error rate of less than 5% of reading with repeatability greater than 1 percent of reading. The Triton 28 www.pacetoday.com.au OCTOBER 2012

TR8’s sensor features a multi-path optical assembly. The first pathway is inside the sensor to a reference detector that compensates for changes in the LED light source caused by aging or other variables. The second pathway has a short path length through the sample, which is best for high concentration measurements. The third pathway has a longer path length, which is best for lower concentrations. Lear Siegler Australasia 02 9531 5444 www.learsiegler.com.au

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How to read a regulator flow curve A flow curve illustrates the regulator’s range of capabilities at one glance. Once you understand a flow curve it is easy and very quick to read, writes Bill Menz.

HE best way to select a regulator for your application is to examine its flow curve, which is often provided by the manufacturer. “Flow curve” is a misleading name. You could easily call it a “pressure curve” instead, since a regulator controls pressure, not flow. The curve represents the range of pressures that a regulator will maintain given certain flow rates in a system. When selecting a regulator, you are not just looking for the right size. You’re looking for a set of capabilities, which is a function of the regulator’s design. A flow curve illustrates the regulator’s range of capabilities at one glance. Once you understand a flow curve – and we’ll explain how – it is easy and very quick to read. Unfortunately, a more common way to select a regulator is to consult its flow coefficient (Cv). If the system flow is within range of the Cv, some people may believe that the regulator is the

No regulator can produce a perfectly flat line over the full range of pressures because the internal components of the regulator have limitations.

right “size.” But that is not necessarily true. The Cv represents the regulator’s maximum flow capacity. At maximum flow, a regulator can no longer control pressure. If you’re expecting flow rates to reach the regulator’s Cv, it is probably not the right regulator for your system. Let’s discuss how to read a flow curve. We’ll cover the basics first and then some of the complexities, including droop, choked flow, seat load drop or lock-up, hysteresis, and accumulation.

The basics

is not controlled by the regulator. It is A regulator’s main purpose is to maincontrolled downstream by a valve or tain a constant pressure on one side flow meter. The curve shows you how of the regulator even though there is a a regulator will respond as flow in the different pressure or fluctuating pressystem changes. sure on the other side. In the case of a Let’s look at the top curve in Figure pressure-reducing regulator, you control 1. The curve starts at 28.6 bar. This is the downstream pressure. In the case of the original set pressure for the regua back-pressure regulator, you control lator. No adjustments are made to the the upstream pressure. regulator, yet the curve shows a change For now, let’s talk in terms of presin pressure. sure-reducing regulators since they are The regulator is making adjustments, more common. Later, we will provide trying to maintain the original set some direction for selecting back-prespressure as flow changes. But, it is not sure regulators. perfect. No regulator is. As system flow A flow curve illustrates a regulator’s increases, pressure downstream of the performance in terms of outlet pressure A D _ P A C E C O N O C T _ 1 2 . pregulator df Pdrops. a g eThe1important 1 3 / ques0 9 / 1 2 , > (Y axis) and flow rate (X axis). Flow tion is: How much does it drop?

FIGURE 1: Manufacturers often provide multiple flow curves for the same regulator at different inlet pressures to provide a range of the regulator’s operating capabilities. OctOber 2012 www.pacetoday.com.au 29

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Any given regulator can produce a nearly infinite number of curves so you need to make sure you are looking at the right one. When reading a flow curve, first identify the range of flows that you can expect to see in your system. Mark these on the graph. Then, look to see what the corresponding changes in outlet pressure will be. Is that range of pressures acceptable to you? If not, you need to look for a different regulator. Ideally, you want to operate the regulator on the flattest part of the curve. There, the regulator will maintain relatively constant pressures even with significant changes in flow. At the far ends of the curve, there are steep drops, where pressure AD _ P A will C Echange C O N dramatically 2 OCT _ 1 2 . p d f with even the slightest change in flow.

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PRODUCTS: When selecting a regulator you are looking for a set of capabilities which is a function of the regulatorâ&#x20AC;&#x2122;s design.

You do not want to operate the regulator at these locations. Any given regulator can produce a nearly infinite number of curves, so you need to make sure you are looking at the right one. For every set pressure, there will be a different curve. In Figure 1, there are two main sets of curves: one based on a set pressure of 28.6 bar and one for a set pressure of 14.8 bar. It is helpful when a manufacturer provides more than one set of curves representing the range of set pressures possible with a particular regulator. If your set pressure lies between the curves, you can interpolate. Note that the two curves are close to the same shape but in different locations on the graph. There is one additional variable that affects the shape of a curve â&#x20AC;&#x201C; inlet pressure (i.e., pressure going into a

pressure-reducing regulator on the upstream side). Note that for each of the two sets of curves in Figure 1, there are three curves representing a range of inlet pressures. In sum, to locate the right curve for your system, look for (1) the right set pressure; (2) the right inlet pressure; and (3) the right range of flows. Finally, make sure you are looking at the right units. Pressure readings are provided most commonly as bar (or psig). Flow rate units vary depending on the system media, so be sure to note whether the regulator is rated for liquid or gas service. Liquid flow is typically expressed as litres per minute (L/min), while gas flow is conveyed as standard litres per minute (std L/min). Curves are usually created using air or nitrogen (for gas service) or water (for

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liquid service). If your system media is a gas, you may need to make an adjustment in the manufacturer’s curve. Gases compress at different rates, so you may need to multiply the flow curve’s volume units by a gas correction factor. For example, hydrogen’s correction factor is 3.8; meaning 3.8 molecules of hydrogen have the same volume as one molecule of air. Therefore, the point on a flow curve showing an air flow volume of 2832 std L/min indicates a comparable hydrogen flow of 10,760 std L/min. The curve stays the same, but the flow scale will change. For liquids, the difference in flow between water and a different medium is not as dramatic due to the incompressibility of liquids.

Droop and choked flow

As mentioned above, it is best to operate along the flattest – or most horizontal – part of a flow curve. Indeed, the ideal flow curve would be a flat line. typical However, noAregulator canMproduce a 2 . p FIGURE AD_ P C E D WY AR_ 1 df P a2:g This e 1 1 0flow / 0curve 1 / 1for 2 a, pressure-reducing 9 : 4 0 A Mregulator demonstrates several phenomena, including the ideal operating area, droop, choked flow, seat load drop or lock-up, and flow coefficient (Cv). perfectly flat line over the full range >

OctOber 2012 www.pacetoday.com.au 31

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Avoid operating the regulator on the far ends of the curve where undesirable conditions like lock-up and choked flow occur.

of pressures because the internal components of the regulator have limitations. In a spring-loaded regulator, longer springs produce flow curves with broader horizontal sections. Dome-loaded regulators, which use a trapped volume of gas instead of a spring, produce even broader horizontal sections. Electrically controlled pneumatic-loaded regulators and domeloaded regulators with external feedback produce the broadest horizontal sections. of /hysteresis that Poutlet Typically, consists A D _ P AaCflow E Bcurve URJ U L _of1 2 . p FIGURE df P a3:g The e phenomenon 1 2 7 / 0 6 1 2 , reveals 2 : 3 8 M pressures will be higher at the same flow volume when decreasing flow compared to when increasing flow. (Hysteresis shown larger than actual for demonstration purposes.) three parts: (1) a relatively flat part in

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TECH TALK

Regulator flow curve terminology o Accumulation: The increase in inlet pressure required to obtain a specified flow rate for a backpressure regulator. o choked-Flow Area: The area of a flow curve in which flow demand is greater than the pressure-controlling capabilities of the regulator. o Droop: The outlet pressure change from the set pressure that occurs as flow rate increases for a pressure-reducing regulator. o Hysteresis: The difference between flow curves for increasing and decreasing flow. o Lock-Up: The outlet pressure increase that occurs as flow is decreased to zero. o Seat Load Drop: The initial pressure drop experienced when a regulator starts from a no-flow state.

the middle; (2) a steep drop on the far left; and (3) a steep drop on the far right. The flat part in the middle is not perfectly flat. Usually, it slopes downward, and this OPTIMUM: A domeloaded regulator with external feedback produces the broadest horizontal sections for a purely is called droop. As flow increases, presmechanical pressure regulator. sure will drop some – or a lot depending on the regulator design. While droop is relatively modest along the flat part of the curve, it is quite steep at the far ends exceeded the pressure-controlling capaineffective. It is not advisable to operate Seat load drop occurs on the far left of the curve. bilities of the regulator. a regulator in the choked-flow area due of the regulator curve (Figure 2), where Choked flow occurs on the far right Here, the regulator is wide open to the sharp pressure drop. there is initially a steep drop in pressure. of a curve. See the choked-flow area in and is no longer regulating pressure. It Note that Cv is measured at the If you are reading the curve from left Figure 2, where pressure begins to droop has essentially changed from a pressureregulator’s fully choked point, and to right, imagine that the system is in a sharply at 3964 std L/min. Eventually, controlling device to an open orifice. that’s why it is not an especially useful no-flow state. The regulator is set to a nearA 4248 this7 / 1 2 , measurement. certain pressure, but there is no flow. D _ PstdA L/min, C E S Ipressure C A Udrops G _ 1to2 . p Increasing df P adownstream g e 1 flow 1 6 to / 0 8 : 4 3 It A is Ma poor indicator of a > zero. At this point, the flow demand has point or beyond renders the regulator regulator’s overall performance. Then, imagine that an operator

Turning heads: the PBS pressure Switch from SICK P00000880_PBS_Ad.indd 1

Universal - versatile - better - the only option! The PBS is an electronic pressure switch, pressure transmitter and display in one. With up to three output signals, a multitude of process connections, double rotatability of the housing and complete pressure measuring ranges for gauge pressure, absolute pressure and vacuum ranges, it is the optimum solution for all machine construction and engineering requirements. • Now available with flush mount membrane • The one unit for so many applications & environmental conditions For more information please visit www.sick.com.au or call 1800 334 802 (Tollfree). 10/07/2012 1:46:18 PM OctOber 2012 www.pacetoday.com.au 33

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IN FOCUS

accumulation (see Figure 4), which is the opposite of droop. Because a backpressure regulator controls inlet pressure, pressure will go up as flow increases instead of down as in a pressurereducing regulator. This phenomenon occurs because the back-pressure regulator acts as a restriction and essentially limits flow at the inlet. Your objective is the same as it is with pressure-reducing regulators: to operate on the flat part of the curve.

Conclusion

FIGURE 4: The flow curve for a back-pressure regulator indicates accumulation, which is the opposite of droop. slowly opens a downstream valve to initiate flow. Right away, there is a sharp drop in pressure because it is difficult for a regulator to maintain pressure at this location. If your regulator is operating along this steep drop in the curve, you may hear chattering or pulsating as the regulator fluctuates between flow and no-flow conditions. Now let’s read the curve from right to left. Imagine that the system is operating along the flat part of the curve. Then, imagine that an operator is slowly closing a downstream valve, reducing flow to near zero. We are moving up the curve. As we near the no-flow state, the regulator has difficulty maintaining the set pressure. Again, you may hear chattering. Eventually, the regulator snaps shut, stopping flow. This is called lock-up. The terms seat load drop and lock-up are essentially interchangeable. Sometimes, people use lock-up to describe both conditions. It is not advisable to operate a regulator in this area.

Hysteresis

It matters whether you are reading a flow curve from left to right or right to left. When reading left to right, flow is increasing. And the reverse is true when reading right to left. Depending on whether flow is increasing or decreasing, the curve will be slightly different. Outlet pressure will not follow the same “droop line,” nor end at the original set pressure. This phenomenon, which is

illustrated in Figure 3, is called hysteresis. The upper line is for decreasing flow, while the bottom line is for increasing flow. Hysteresis, which results from dynamic friction forces within the regulator, is usually not an issue when evaluating the performance of a regulator. However, it can be a point of confusion during system operation. Suppose an operator sets up a system to deliver an outlet pressure of 4.461 bar at 3115 L/min. The next day, he notices that the pressure is now 4.495 bar, but the flow is still 3115 L/min. Hysteresis is to blame. It is likely that something in the system temporarily created more flow demand downstream. Moving from left to right on the curve, the temporary flow increase slightly reduced the outlet pressure. Then, as the flow demand returned to 3115 L/min, hysteresis caused the outlet pressure to return to a point slightly higher than the initial set point. This scenario illustrates the need for operators to periodically check systems to ensure regulators are set to the proper outlet pressures. It is recommended to approach your set pressure from a lower pressure. Another best practice is to employ pressure gauges in a system to help fine tune regulator settings to achieve desired operating pressures.

curve. On the curve, identify the range of flows you can expect in your system. Given that range, the curve will tell you what pressures you can expect the regulator to maintain. Ideally, you want the regulator to operate along the relatively flat part of the curve. That’s where the regulator will perform most consistently. You want to avoid operating the regulator on the far ends of the curve where undesirable conditions like lock-up and choked flow occur. If a flow curve is not available, or if you need help selecting a regulator, consult with a knowledgeable sales and service representative who can provide guidance on properly sizing a regulator for your application. [As manager, field engineering, Bill Menz (Bill.Menz@Swagelok.com) leads a team of engineers dedicated to supporting application, service and training of Swagelok products.]

When selecting a regulator for your application, consult the flow curve, not the Cv. Make sure you are looking at the right curve. Does it reflect the pressure you will set your regulator to (your “set pressure”)? Does it reflect the right inlet pressure range? Are you working with the right units? Do you need to calculate any adjustments if your system media is a gas? Once A D _these P Aissues C E Vhave A Lbeen SEP_ 1 2 . pdf addressed, you can start reading your

Swagelok 08 8369 P a g e 1 8 / 0 8 / 0899 1 2 , www.swagelok.com.au

Back-pressure regulators

Flow curves for back-pressure regulators reveal a phenomenon known as OctOber 2012 www.pacetoday.com.au 35

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SPOTLIGHT

7best of the

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

Accurate ultrasonic controllers Siemens has released a new series of ultrasonic controllers with 1 mm measuring accuracy. The SITRANS LUT400 series controllers are compact, single point, long-range ultrasonic controllers for continuous level, or volume measurement of liquids, slurries and solids. They deliver high accuracy monitoring of open channel flow. They are also suited to applications such as wet wells, reservoirs, flumes/weirs, chemical storage, liquid storage, hoppers, crusher bins and dry solids storage. The SITRANS LUT400 comes in three different models to match the application, level of performance and functionality required: SITRANS LUT420 level controller measures the level or volume of liquids, slurries, and solids, and conducts basic pump control functions and basic data logging capabilities. SITRANS LUT430 is a level, volume, pump and flow controller. It includes all the features of the LUT420 plus a full suite of advanced pump control and alarm functionality, open channel flow monitoring, and has basic flow data logging capabilities. Siemens 137 222 www.siemens.com/sitranslut400

Total organic carbon sensor with ISM The Thornton 5000TOCi sensor with Intelligent Sensor Management (ISM) enables continuous, fast, and reliable monitoring of total organic carbon (TOC) levels in applications such as Water for Injection, reverse osmosis membranes, effectiveness of TOC destruct UV lamps, resin bed performance, organics shedding, and quality of final rinse water. With fast response continuous on-line measurements, the 5000TOCi sensor ensures TOC excursions will not be missed. The

5000TOCi sensor is developed specifically to meet the demands for pure water in the pharmaceutical, power generation and microelectronics industries. When combined with Thornton’s M800 multi-parameter transmitter, it integrates on-line TOC measurement with up to four sensors to save cost and complexity. The new M800 transmitter offers mixand-match sensor capability. Mettler-Toledo 1300 659 761 www.mt.com

Modular multi-channel MultiCELL 8619 The modular multi-channel MultiCELL 8619 is designed with standard functions and extension modules to customise the transmitter/controller to specific application needs and connected sensors. A new extension module has been released, as a new signal input board that can be used for direct connection of two additional digital-input flow sensors, and two additional analogue-input measurement devices. The new signal input board features two 4-20 mA signal inputs for any type of transmitter with a suitable signal output, such as measuring pressure, level, or water chemistry parameters including turbidity, oxygen, free chlorine, 36 www.pacetoday.com.au OctOber 2012

ozone. These analogue inputs can be locally altered to 0 … 5 V or 0 … 10 V inputs. The board is equipped with two digital NPN and PNP transistor inputs for the connection of transmitters with frequency output, such as flow transmitters. Alternatively the digital inputs can be used as contact inputs to trigger selected functions of the 8619. The Type 8619 transmitter is delivered pre-commissioned, with the user parameterising inputs, and selecting scaling and units as required. Bürkert Australia 1300 888 868 sales.au@Burkert.com

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

Martel pressure calibrators for EX applications Zedflo are now supplying approved intrinsically safe versions in the Martel family of advanced pressure calibrators, with the BetaGauge 311A-EX (single sensor) and 321A-EX (dual sensor) models. The classified hazardous area approvals include IECEx and ATEX certification for worldwide use. In addition to the approval to safely use the calibrators in hazardous areas without â&#x20AC;&#x153;hot workâ&#x20AC;? permits, the EX versions include a new graphic LCD with intense backlight for a crisp black on white display. The Martel 3 key user interface is supported by a multi-mode operating system that allows a range of operations from simple measurements to complex calibration applications. As in the standard units, the calibrators are available in the userâ&#x20AC;&#x2122;s choice of 25 available pressure ranges from 2.5 kPa to 68 MPa in compound, gauge, differential and absolute modes.

Real-time remote Wi-Fi troubleshooting and spectrum analysis Fluke Networks has announced a new remote analysis capability for its portable wireless LAN (WLAN) tools, making them the first to enable both real-time troubleshooting and spectrum analysis of remote wireless networks. This lets organisations with remote sites that do not need WIDS/ WIPS 24/7 monitoring to resolve connectivity and interference problems, identify rogue devices and detect security violations without having to make expensive site visits. The remote analyser solution is comprised of AirMagnet WiFi Analyser PRO 10.0, AirMagnet Spectrum XT 3.5.1 and AirMagnet Series Sensors. Sensors can be deployed to remote sites and then be monitored via WiFi Analyser PRO or Spectrum XT at a control site. Fluke Networks sales@fluke.com.au www.flukenetworks.com

CO2 transmitters based on NDIR A high concentration of CO2 in the environment causes humans to rapidly fatigue and suffer loss of concentration. It is important in modern climate control systems to measure not only parameters such as relative humidity and temperature, but also the CO2 content. The concentration of CO2 is regarded as an important indicator for the quality of room air. Rotronics new range of CO2 transmitters are based on the NDIR (Non-Dispersive Infra Red) measuring principle. All probes are pre-calibrated and have a lifetime of over 15 years in normal applications. Automatic baseline correction means sensors require no further calibration if used in indoor air applications.

Zedflo Australia 08 9302 1266 sales@zedflo.com.au

Pryde Measurement 1800 688 211 info@pryde.com.au

Distributed frequency inverter series SK 200E series frequency inverters provide solutions with adaptable functions for any application within a distributed automation concept where cost-efficient drives with a performance between 0.25 and 22 kW are required. Available for installation near the motor or as motorintegrated models, various types cover typical distributed applications. Frequency inverters from the SK 2x0E line are equipped with a process and PI controller, and qualify for use with fans and pumps through their internal 24V power supply and two analog inputs. The SK 2X5E line is tailored for the needs of conveyor technology. Inverters from this series are equipped with a brake controller and two inte-

grated potentiometers which allow for easy adaptation to the requirements of any drive task. Due to standard features such as speed feedback and a positioning function, these inverters can also independently and precisely control positioning and lifting tasks. The units are performance-graded and can be fitted with various optional add-on functions, allowing users to choose suitable compact devices with the exact feature range for any given task, thereby optimising resource use. NORD Drivesystems au-sales@nord.com 03 9394 0500 www.nord.com OCTOBER 2012 www.pacetoday.com.au 37

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COMMUNITY

WHAT’S ON

TOP TWEETS

PlantStruxure NOW! 9-11 October 2012, Gold coast events.schneider-electric.com.au/now IICA Sydney Technology Expo 2012 10 October 2012, Strathfield nsw@iica.org.au Machine Safety Training 10 October 2012, Newcastle newcastle.events@inaco.com.au PLM Innovation Americas 2012 25-26 October 2012, Georgia, USA www.plminnovation.us Certified PROFIBUS Training 29 October to 2 November profibusaustralia.com.au IICA @Home Event at WIKA Australia 30 October 2012, Sydney nsw@iica.org.au

For daily updates visit www.pacetoday.com.au

Here’s what you may have missed this September if you weren’t following @pacetoday on Twitter: o Market for control valves using electric actuators to double by 2017 http://dlvr.it/29y3cM

o ABB wins US$140 million order to automate largest iron ore mine http://dlvr.it/27zLMd

o Suite of iPad apps to help business http://dlvr.it/29xkNt

o Australian manufacturers urged to pursue Indonesian automotive aftermarket http://dlvr.it/27Ng9k

o Lean automation solutions to see high growth over next five years http://dlvr.it/29djXQ

o Pump designers rank improving design efficiency as number one http://dlvr.it/27NY3f

o Victorian government faces TAFE backlash http://dlvr.it/29LyJv

o Desalinate sea water using 50 percent less energy http://dlvr.it/26dDcN

o CNC platform provides machine tool manufacturers with configuration flexibility http://dlvr.it/29Ltrm

o Advatek awarded $243,000 grant to install energy efficient CNC machines http://dlvr.it/260rb7

o Fieldbus Foundation updates HSE Interoperability Test Kit http://dlvr.it/28JD1S

o Swagelok acquires IPT and broadens valve line http://dlvr.it/2601Lx

o Autodesk offers first cloud-based pay-as-you-go simulation http://dlvr.it/28HymW

o Schneider Electric to acquire Adelaide-based scientific software provider http://dlvr.it/25rK9m

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

IICA CORNER

Reaching out to students Need unique initiatives to attract next generation to an IC&A career, writes Brett Simpson. I WANT to outline some of the initiatives that the Institute of Instrumentation, Control and Automation (IICA) is currently leading. Those are to do with raising awareness, interest and explaining the possibilities of pathways to interesting and rewarding careers in the areas of instrumentation, control systems and automation (IC&A). The focus of each initiative is therefore firmly fixed on schools and tertiary institutions. The first initiative is one that my colleagues in Western Australia have been undertaking for a number of years and focuses on secondary schools. The IICA Perth Branch has developed relationships with these institutions, mostly via careers teachers. It involves a number of IICA Members making presentations 38 www.pacetoday.com.au OctOber 2012

to students about instrumentation and related areas. The presentations explain, in simple and arresting ways (using the aptly named ‘bang box’ as one of their visual aids) some of the principles and characteristics of particular instrumentation and control systems. The presenters have a clear vision of their message and have the ability to generate interest and attention from their youthful audiences. Another initiative that has also emanated from our Perth Branch, is the development of a number of extremely professionally produced and punchy videos which portray a number of young graduate men and women talking about their exciting and rewarding jobs within different IC&A fields. Each video is made using real young

persons who are genuinely excited and enthusiastic about their newly acquired careers, and their spontaneity shines through each presentation. Those young men and women and their personal stories serve as aspirational role models to other young graduates considering their own career options. The last couple of examples are ones that the majority of IICA Branches have taken up as part of their ongoing annual Branch activities. They include participation at various Careers Expos. Engineers Australia has for some years now organised State based Expos and the IICA Federal Council has agreed that such opportunities would sit comfortably within the Institute’s overall Educational and Networking aims of establishing and

fostering links with students interested in engineering related career goals. The IICA has generated with positive relationships with a number of tertiary institutions that offer qualifications in the broad IC&A discipline areas. Those relationships range from sponsoring prizes for best students in particular subjects to organizing student beer and pizza nights and encouraging tertiary final year students to join the IICA as Student Members with free Membership. These initiatives raise awareness and visibility of our Institute and also assist in ensuring that there is a continuing stream of young persons enthusiastic and actively wanting to take up IC&A careers in the future. [Brett Simpson is President IICA.] admin@iica.org,au www.iica.org.au

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