PACE - Process & Control Engineering - September 2011 by Prime Creative Media

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PACE PROCESS & CONTROL ENGINEERING

Batting for Profibus Solar generated power could provide significant amounts of clean energy. Conversation 12

AIMEX 2011 Preview Mining offers major opportunities for process control and automation. Special Report 18

Manufacturing sustainably ZZZ DQ\EXV FRP DX SEPTEMBER 2011

VOL.64 NO.8

INSIDE THIS ISSUE FOR: OFFICIAL MAGAZINE

INSIDE THIS ISSUE

Opinion 6

How will MESA benefit us? A knowledge of Manufacturing Enterprise Solutions will give Australian companies a competitive advantage in the market place. Special Report 20

Enhance process insight Advanced Diagnostics embedded in a pressure transmitter proactively detects abnormal process conditions. IICA News & Views 30

Benefit from the IICA The IICA functions as a neutral body and helps in bringing together individuals and corporate entities.

BY KARSTEN HOJBERG MANUFACTURERS in Australia face mounting pressures to not only increase productivity in the manufacturing process, but to ensure more sustainable manufacturing outcomes as well. Two factors reduce the risk of updating a production process to improve its sustainability – one is using a proven methodology and the other, a proven technology. Lean Manufacturing and SixSigma are well-known process improvement methodologies that target and eliminate waste to drive profitability; they usually improve the environmental performance of a process at the same time. The other way to reduce risk is to take advantage of the latest software technology. Businesses that use a design platform with digital prototyping capabilities can develop a single 3D model that evolves from concept through manufacturing. The model allows the designer to evaluate opportunities to reduce environmental impact throughout the manufacturing process – for example, by reducing weld energy through optimisation of material thicknesses in an assembly. Industrial equipment, consumer electronics, mobile phones – anything with an on/off switch –may consume many times more energy in a year than was consumed during its production or embedded in its raw materials. In other cases, the choice of materials may be the most critical environmental factor associated with a product. Both issues are of growing importance to customers, supply chain partners and regulators. Products with low eco-footprints offer a lower total cost of owner-

HOJBERG: Software can help improve the sustainability of manufacturers. ship, less chance of liability and fewer regulatory hurdles for producers and buyers alike. Sustainable design practitioners work backward and analyse the impact of material choices and production processes on the product’s overall sustainability and the desired outcome. Once the desired outcome is selected (for example lowering energy use during production by 20 per cent), the design team can pick a strategy (reduce the number of heat-treating operations) and analyse the inputs and process steps to understand the impact of each on the outcome. The team can then integrate all design data into a single digital model, streamlining the design process and improving communication. As the model develops it becomes a more accurate digital prototype of the product, reflecting the material attributes

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such as weight, strength and recycled content, and process attributes such as energy intensity and water consumption. As the product design evolves from concept through engineering and on to production, it can be tested, modified and optimised to achieve the desired outcome. Sharing a digital model among multiple team members throughout the process helps keep them aligned and focused on achieving the intended result. Regardless of the specific sustainable outcome and strategy selected, a digital prototype will save the design team time and money as it analyses and tests alternative options. In many cases, the digital prototype can help predict the impact of the proposed change on the product’s characteristics and the energy consumed during its manufacture. Armed with such data, the design team can quickly and cost-effectively experiment with different material and process variables until it discovers the optimal combination. Multiple options for the same product can be saved at any stage, from concept through manufacturing, allowing the team to pursue multiple strategies in parallel. If the market or regulatory environment changes, the product can quickly be optimised to meet the latest conditions. The digital prototype reduces risk by allowing the design team to incorporate changes much later in the process, increasing design decision flexibility to support sustainable product strategies. [Karsten Hojberg is Director of Manufacturing Solutions, Autodesk Australia & New Zealand] www.autodesk.com.au/digitalprototyping

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EDITOR’S MESSAGE

PACE

Desal decisions

PROCESS & CONTROL ENGINEERING

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Next Issue Instrumentation Discrete Control ● Process Control in Food ● Sensors & Analysers ● ●

THE International Desalination World Congress is being held in Perth this month and it’s an opportune time to turn the spotlight on water. The country’s first desal plant was commissioned in Perth just five years back. We now boast six major seawater desalination facilities with a total capacity of 1.6GL/day. And Perth is set to get its second one at Binningup. At home, they are dogged by controversy, union shenanigans, cost blowouts, rising water prices and political drama. But Australia’s desal plants are winning high praise overseas. According to the Congress organisers, Australian plants have set new benchmarks for environmental performance, reducing impact of intakes and outfalls and plant location. Operational carbon footprint has also been reduced by purchasing wind powered renewable energy to offset energy consumed. The huge amount of power consumed in the desalination process has always been an area of concern. But recent advances in energy recovery from the Seawater Reverse Osmosis (SWRO) brine stream has contributed to improved sustainability of desal

plants, decreased energy needs and a reduced carbon footprint. In a short span of five years, Australia has developed significant expertise in many areas. The next five years will be different, though. We’ve passed the frenetic desal building phase and will focus more on energy management and efficiency. Even globally, forecasts indicate a slowdown in the construction of new desalination plants, impacted no doubt by the gloomy economy and the unexpected wet weather. The worldwide market, valued at $7 million, is however expected to rise once again and will double by 2016 although most of this growth will be outside Australia. However, this optimism has not rubbed off on the world’s largest water company. Veolia’s shares have been taking a beating and the erstwhile darling of the stock market and water funds is on a downward spiral. A GWI columnist has this to recommend: Veolia needs to move from a multi-national to a multi-domestic management structure and act like a local wherever it operates. Kevin.Gomez@reedbusiness.com.au

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Discrete machine safety components getting smarter END users and machine builders are increasingly looking for better diagnostic and networking capabilities in discrete machine safety components, according to a survey carried out by IMS Research. These results are supported by a separate market study published by IMS Research at the beginning of 2011. This study, Discrete Machine Safety Components - World - 2011, forecasts that revenues for touchless switches are set to grow by an average of nearly 20% per year, leading to total revenues of US$128 million by 2014. Revenues of traditional (mechanical and solenoid) switches are forecast to grow by only 1%

annually. Although implementing ‘intelligent’ safety systems does present higher initial costs, it offers some significant benefits to users. Improving diagnostics allows faults to be identified early and parts to be replaced before a major failure occurs. Implementing networking allows these early warning signals to be delivered to a central monitoring station allowing further potential time savings. These improvements should reduce both down-time and operator injuries. Ever increasing numbers of end users and machine builders are switching to the more intelligent discrete machine

safety component options. This will not only help to increase revenues for safety component suppliers, but will also improve productivity while ensuring the safety of operatives on the factory floor. “A good example of this is the projected increase in the use of touchless interlock switches, which often provide diagnostic and networking capabilities,” comments IMS Research market analyst Graham Brown. “Twice as many respondents currently use traditional types of interlock switches. However, by 2014 more respondents intend to use touchless interlock switches.” www.imsresearch.com

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Sensor project gets $2.3 million grant

❏ Smart grid integrates Australia’s first community owned wind farm. http://dlvr.it/dSMjf

THE Greenhouse Gas Monitor project, led by Vipac Engineers & Scientists has received a $2.3 million grant from the Government’s Australian Space Research Program. Vipac will work with the Australian National University, the universities of Wollongong and Melbourne, the Bureau of Meteorology and Melbourne-based Rosebank Engineering. The project aims to develop an innovative sensor to measure greenhouse gases nationally and globally. The project will tie the measurements to observations by satellites in order to provide global coverage. Additionally it will develop modelling and analysis tools to interpret the data, thereby advancing scientific understanding of the carbon cycle and providing policy relevant information of sources and sinks of greenhouse gases. The improved information on the distribution of carbon dioxide in the

❏ Discrete machine safety components are getting smarter. http://dlvr.it/fYncc ❏ Nestle chooses openSAFETY as standard for packaging machines. http://dlvr.it/fGWDN ❏ Local gas sensor project gets $2.3 million grant. http://dlvr.it/dnd7X Follow @pacetoday on Twitter for the latest news, analysis, new product information and commentary. And never miss out again.

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atmosphere resulting from the project will mean better monitoring and management of the roles of agriculture, forestation and deforestation as CO2 sources and sinks. It will also deliver more reliable weather forecasts and more sensitive detection of climate change. The project will also increase Australian capability in the design, build and test of advanced remote sensing instruments. Vipac is a multi-disciplinary technical consultancy specialising in mechanical and systems engineering, testing and instrumentation. The company hosts runs a NATA accredited laboratory testing and has capabilities in acoustics, vibration, fluid mechanics, thermo-dynamics and system design. The Federal Government believes that space science is no longer about a race to the moon but about helping tackle quality-of-life issues such as weather forecasting and changing

climate. The project is part of the Government’s Clean Energy Future initiative. Two other projects were awarded to ANU and UNSW. The ANU will partner with national and international industry bodies to develop a better propulsion system for satellites and deep-space missions. The $3.1 million in funding will also help build a space simulation facility at the ANU. The facility will be a research hub for space scientists, astronomers and industry bodies looking to develop space equipment. UNSW will partner with national and international space industry bodies and use their $675,000 grant to formulate and deliver a two-year Masters degree program in satellite systems engineering. This will address the current education gap and help prepare graduates with industry experience for Australia’s developing space industry. www.vipac.com.au

OPINION

COLLABORATIVE PROCESS AUTOMATION

Historians are evolving Process historian suppliers are moving in the right direction, writes Dave Woll.

S EXPLAINED in ARC’s updated, Collaborative Process Automation Systems (CPAS) study, process historians provide key functionality within ARC’s overall CPAS vision. Although it appeared that process historians – along with process automation systems in general – have had a period of slow progress, we’re now seeing specific activity that provides a strong indication that process historian suppliers are moving in what ARC believes is the right direction. In fact, a handful are getting very close to becoming the object-based, enterprise-wide, operations-centre-like, process historian described in the “CPAS 2.0” study. Historically, process data historians have been the plant manager’s favourite tool for understanding how the plant is performing. Initially, data-driven time series tabular displays and trends were sufficient. However today, many users at both the individual plant level and across the enterprise want to be able to collaborate and project their understanding based on a single version of the truth. They want to be able to harvest any relevant information assets without boundaries in real time and work collaboratively with business counterparts and colleagues at their sites and in other plants using a comprehensive, state-of-the-art toolset and a common understanding. They want to become knowledge workers with unfettered access to data and relationships through tools that can deliver a common and precise understanding of the production cycle in context, which is the foundation for productive collaboration. This requires a single version of the truth, a cornerstone of the CPAS vision. With the last generation of process automation systems, a common theme was, “he who owns the data wins”. This limited potential performance. Instead, everyone with a need to know should have access to the data. The 6 www.pacetoday.com.au SEPTEMBER 2011

shift operators will experience no emergencies or crisis 95 percent of the time. But havoc and uncertainty can prevail during the remaining five percent. This five percent (and perhaps the 10 percent preceding the havoc) represents the opportunity cost in not having a better understanding of manufacturing and work processes. This doesn’t bode well for the future, since the major factors limiting these losses are experience and good judgment. The big difference between your current “best operator” and the next operator that will replace him or her, is experience and judgment. At this point in time, the situation does not look so good. However, in the near future, when the experience and judgment retires, it will look even worse. theme for today’s system should be, “everyone should own the data”. But incremental performance is a function of how individuals deal with the unknown or misunderstood data.

Trends and Challenges Historically, process manufacturing plants have been operated so that steadystate operations are maintained in the face of multiple disturbances and rate or grade changes. Operations involved doing what is required to keep the plant running and meet production schedule and product quality specifications in a safe and environmentally acceptable way. Although some facilities still operate in this mode, the next-generation plant does not. The economics of steady-state operations are being replaced with a dynamic economic environment in which adapting to changing supply streams, creating multiple products, and frequent transitions from product-toproduct or grade-to-grade are the norm. Tighter quality specifications and the need to maintain minimum inventories, plus more stringent process safety measures, cyber security standards, and environmental regulations further constrain this dynamic environment. Effective manufacturing in today’s

Many users at both the individual plant level and across the enterprise want to be able to collaborate and project their understanding based on a single version of the truth. process industries requires real-time decisions, rooted in an understanding of what is happening and the possibilities over the entire production cycle. Many plant managers use their historians to understand what has happened, their intellect and experience to understand what is happening, and an educated guess as to what will happen. Relative to risk management, this is not acceptable. Plant managers need tools that define precisely what is happening, what will happen, and if the current trajectory is leading to an unacceptable result, what needs to change to achieve an acceptable result, thus providing the opportunity to take corrective action. In a well-controlled process plant,

Next steps In the past, the historian was used to aggregate data and act as a passive data server to Level 3 and Level 4 applications as well as perform historian and limited analytical functions. Today, we see the CPAS historian as a station on a message bus adding value to peer applications. This enables advanced, high-availability computing and the associated benefits. The CPAS historian broadens the concept of a “single version of the truth” from the plant to the enterprise. This facilitates a broader range of collaboration and precision. The solution also provides an excellent platform for business intelligence and appears to be evolving into a platform to enable true operations centre functionality for a plant or set of plants. In the context of an operations centre, the CPAS historian can transcend the manufacturing domain in a regional or divisional configuration and promote a higher level of collaboration between manufacturing and business operations. [Dave Woll (dwoll@arcweb.com) is Vice President Consulting Services, ARC Advisory Group.] www.arcweb.com

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CONVERSATION

JUSSI RAUTEE

ABB is poised for growth Jussi Rautee outlines the opportunities and challenges ABB Australia faces. By Kevin Gomez PACE recently caught up with ABB’s Jussi Rautee in Melbourne and got some insight into the ambitious plans for the company’s Discrete Automation and Motion division. How has the Baldor acquisition changed ABB? Baldor has brought a lot of new products and channels to the ABB portfolio; primarily in the US market especially since we were not so strong in the motor business in that region. Secondly it brought a lot of new products to our offering for discrete manufacturing and mechanical power transmission. In the past we had PLCs, robots, motors and drives. But now we have the

complete range: servo motors, drives, motion and industrial controls, robots, gears, bearings; everything that system integrators might need when they’re building solutions for their customers. Are we going to see new products as a result of the acquisition? At the moment we are progressing well in integration phase. There will be products in the pipeline from our joint R&D teams, but our first task is to make sure that the integration is done properly, both in terms of people and products. We most make sure our products are speaking with each other – that’s the first step. Our task is to find best practices. I’m

100 percent certain that Baldor do many things better than we do, and there are many things we might do better. Now we need to find those best practices and implement them globally as one big company. How do you rate the Australian market for your products? When I first came here eleven months ago, I was surprised at the size of the Australian market. It’s huge. We have so many opportunities here – much more than people realise. The Australian economy is in the growth phase and we are estimating three and a half percent GDP growth for the next few years, which is very good

for a developed economy especially in this global environment. Of course, it is very much driven by the mining boom but there is also the increasing need in the food and beverage and renewables market. There is also a growing need in the general manufacturing market, especially in productivity improvement projects. With our product offering and our large system integrator network, we can offer good solutions. I have a strong belief – and a dream – that we can triple our sales in next few years. Since you’ve worked a lot in Europe, what differences do you find in the local environment by comparison?

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The first thing that struck me in Australia was that you don’t have much consolidation. If you take a close look, consolidation has not happened here as much as it has in Europe. There are plenty of small operators, manufacturers, customers. I don’t have the statistics but I believe there are several large customers and then there are lots of smaller ones – companies with less than 50 people. But there aren’t so many companies in between. So we need different ways to approach the customer base and different ways to serve the market. Consider this simple example. You go on Saturday morning to buy breakfast for your family. You go first to the bakery and then to the butcher and then you go to the wine shop and the veggie shop. You have supermarkets here but you still have a lot of these independent operators. In Europe this is not so common. We face a very similar market profile when marketing our products and services.

A lot of ABB products are made in your China factory. In Australia, do you receive requests for ‘Europeanbuilt’ products? At ABB everything is made in ABB – we have the same manufacturing standards and suppliers, regardless where the production facilities are situated. Our China facility helps us better serve the local the markets with faster shipments. This is a great asset for Australia. Energy management is a high interest topic in Australia right now. How does this shape ABB’s plans? You have a lot of good legislation in Australia such as minimum efficiency standards for motors, for example. And there is now legislation under preparation focusing on energy efficiency improvement. So, there are still a lot of things that we can do together. In Australia, over 40 per cent of all the electricity goes to the industries. Within industry, in our applications,

We have helped some of our customers reduce their energy bills by 30 to 40 per cent by introducing new technologies to them.

65 per cent of electricity goes to the motors. That’s the average. This figure is higher for many processes. Given this picture, we may think there is a need to invest in additional power generation. But in many cases you can increase your total power consumption but still manage with the same power generation if you increase the efficiency in the middle. There is so much lost from the power plant to the consumer. We have done a lot of work on motors and other applications. We have helped some of our customers reduce their energy bills by 30 to 40 per cent by

introducing new technologies to them. The payback times for initiatives like these could be as little as six months. Recently, we helped Victorian State Library to save more than $100,000 tax payer’s money annually by introducing variable speed drives in a few applications with very good pay-back times. Secondly, I think increasing productivity is a major objective for many Australian companies. If we help them, we can grow together. We also have excellent tools and products to improve process productivity and energy efficiency for example through our robotic services. Energy prices will not go down – they will only going up. I believe our mission is to help our customers improve their productivity and energy efficiency. [Jussi Rautee is Senior Vice President, Discrete Automation and Motion, ABB Australia.] ABB Australia Pty Ltd www.abbaustralia.com.au www.abb.com/drives

SEPTEMBER 2011 www.pacetoday.com.au 9

OPINION

MANUFACTURING ENTERPRISE SOLUTIONS

MESA for Australia MES knowledge will give Australian companies a competitive advantage, writes Alison Koh.

S MANAGEMENT of the supply chain becomes more critical for businesses, the need for flexible and standardised processes and systems becomes more important. Standardising process systems can be achieved through embracing the practices championed by the Manufacturing Enterprise Solutions Association (MESA). In Australia, the mining industry is investing heavily in manufacturing enterprise solutions. However to date, the majority of Australian industries are not as mature in their knowledge of how best to implement and roll out MES capabilities across their supply chain.

Big opportunity The certificates from MESA present a big opportunity for Australian organisations to drive efficiencies and roll out faster and more effective operationsbased business decisions. A key component of MESA is its Global Education Program which fourteen employees from Schneider Electric recently completed. A core component of the program teaches organisations how to best leverage international standards regarding standardising data models, data transactions, interfaces

and security models. A critical learning was the key differences between the maintenance based data models for equipment and the operational equipment model within an enterprise.

Flexibility A common misconception when embarking on an MES project is that the equipment model for maintenance systems should be used as the framework across operations. There can be issues with this approach that can result in reduced production flexibility (or process ‘hardcoding’) and can also lead to costly rework of technology solutions. Through the MESA training, our plan is that this misconception will start to be phased out as businesses learn more efficient ways of approaching these common processes. Another key component of the MESA Global Education Program is the process around Manufacturing Transformation Strategy (MTS), which looks at operational maturity modelling and transformation roadmap modelling. This is about knowing how to transform the business across all aspects of operations – IT, the people (employees), structures and processes. Whilst IT is important, businesses need to understand that technology is

A common misconception when embarking on an MES project is that the equipment model for maintenance systems should be used as the framework across operations. only one part of the change that they need to undertake. Organisations can gain overall improvements in processes across all facets of the business from this aligned approach. The successful launch of the Global Education Program (GEP) in Australia will enable industrial organisations to take advantage of global best practice and embed more flexible, standardised processes, structures and technologies. This will help to facilitate more effective and continuous improvements, drive greater efficiencies, and lead to a much higher level of enterprisewide flexibility.

Excellence Schneider Electric is committed to drive design and implementation excellence in Australia in the MES space.

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There is a significant opportunity for Australian organisations to follow suit and undertake the Certificate of Competency which will help breed best process and operations practice in Australia. Mike James Chair of the MESA Global Education Committee stated: “The response to the launch of the new education program in Australia has been phenomenal. All the words around MES might seem dry or technical, yet do not be fooled. By creating a global understanding of MES methodologies we can connect supply chains worldwide. Schneider Electric, along with other industry suppliers, have seen this opportunity to reduce supply chain costs with a standardised approach. MES knowledge is powerful and will give Australian companies a competitive advantage in our global market place. Alison Koh contributed to the MESA Global Education Program in Europe before moving back to Australia and was one of the initiators of this program along with globally experienced MES practitioners. My message to the Australian industry is: “Take advantage of the MESA Education Programs.” [Alison Koh is Product Manager for SCADA and MES, Schneider Electric, Industry Business.] www.schneider-electric.com.au

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CONVERSATION

FIELDBUSES

Batting for Profibus Andy Verwer offers a rare insight into the world of Profibus. By Andrew Dummett. Andy Verwer set up and ran the first accredited Profibus International Competency Centre (PICC) for the UK. He is no stranger to Australia and is closely involved in the training activities of Profibus Association of Australia and the local PICC. What are the key reasons behind the spread of Profibus? Initially, when it was introduced in the early 90s, Profibus did not dominate the fieldbus market. However, it incorporated all the requirements for implementing reliable multi-vendor systems. The basic specification for Profibus decentralised periphery, or DP, was simple to use and provided a platform that allowed manufacturers to easily develop a fieldbus interface for their products. Because of this Profibus soon became the dominant fieldbus for manufacturing and general automation in Europe. However, other technologies dominated America, the Middle East and Asia, particularly in gas and oil. Profibus International (PI), the user organisation, was very active in developing and extending the standard, adding new features that tightened specifications and allowed Profibus to be used in new areas and applications. PI ensured that all changes and extensions were totally backwardly compatible. Other fieldbusses were also trying to extend their specification of course, but they often made the error of not achieving backward compatibility. The Process Automation, or PA specification was a major addition to the Profibus family that was added in the mid 1990s. This was aimed at the 420mA process control market giving power and data over the same cable, but with Profibus functionality. Profibus PA provides a simple solution for Intrinsic Safely, where there is a risk of explosion. But Foundation Fieldbus (FF) also has power over the bus and can be used in hazardous environments. Why not just use FF? Well, actually there is no difference in 12 www.pacetoday.com.au SEPTEMBER 2011

FF and PA at the physical or wiring level. They both use the same Manchester Bus Powered specification; they both use the same simple concept for protecting against ignition in explosive atmospheres. However, the communication protocol is quite different. FF has its own protocol which is incompatible with other fieldbusses. PA, on the other hand, uses the same protocol as DP. DP and PA can operate on the same network. With FF, a second, high-speed communication is invariably used at higher level. In fact in many instances FF is used together with Profibus DP. Many industries use both process control and higher speed automation. Good examples are found in food, brewing, household product manufacture. Most industries have control systems that extend into both areas and you will often find a mixture of low speed process control and monitoring and high speed materials handling, packaging, storage and warehousing. Are there any other differences? Yes, a major difference between FF and PA is that the FF specification defines a mechanism for the controller to be implemented within the instrument or actuator. PA always implements control at the controller. In practice, this difference is not important, because most users of FF actually do not use the controller in the instrument. For security, reliability and ease of controller parameter access for tuning, users generally prefer to implement control from the control room. The simplicity of the basic Profibus technology means that PA systems are generally easier to set up and perhaps more importantly, to maintain. Surely, different manufacturersâ&#x20AC;&#x2122; devices will have different features. How do these fit in with the PA profile? Yes, of course a particular vendor can incorporate features in their products that that differentiate them from other manufacturersâ&#x20AC;&#x2122;. But, the PA profile defines how this is to be done in a

manufacturer independent way. This keeps the userâ&#x20AC;&#x2122;s view of devices standardised and simple, yet allows additional features to be used in particular devices. A good example is the feature of blocked impulse line detection on differential pressure transmitters. This clever feature allows a DP transmitter to detect the subtle sign of a blocked impulse line to one or both the low or high pressure cell connections. These additional parameters are added within the standard pressure transducer block, which is defined in the PA profile, but in the manufacturer specific parameter area. Another example is the feature of echo curve characterisation in ultrasonic level transmitters. Profibus seems to have had a fair bit of success in mining and in water, globally and even in Australia. Why do you think this has happened? The water industry seems to have similar requirements to process: devices mounted outside exposed to the weather; extensive installations with devices spread over a large area; generally quite slow process reaction times. However, we often see mechanical devices used on screens, filters, for solids removal, cleaning. These devices quite often have similar requirements to manufacturing. Again the hybrid industry argument applies. Mining, again has its own special requirements. However, again the wide range of devices available with a Profibus interface means that generally devices can be procured from a range of suppliers that will meet the need of the industry in a simple and cost effective way. Perhaps these industries have come to realise that a common technology allows common tools and training to be applied across the whole plant. Is there a case for retrofitting fieldbus? Well many companies in the process sector have 4-20mA devices installed and many in manufacturing are using traditional dumb sensors and actuators based on 0-24V switching technology.

These technologies were state of the art when installed, but modern intelligent devices have many advantages. The most obvious advantage of modern fieldbus enabled devices is that it usually has extensive inbuilt diagnostics to report errors in a manufacturerindependent way. This provides very rapid diagnosis of problems and consequently rapid repair. Both Profibus DP and PA support standardised diagnostics that can tell us communications and peripheral errors. They can provide helpful information on identifying and locating errors down to the device, module and channel level. Profibus PA provides properly scaled process values that do not need any scaling or calibration in the controller software. The accuracy and reliability of Profibus device is therefore generally much better than traditional devices. Calibration is also generally much easier to perform and check. What about functional safety systems? Well this is really a different area which is concerned with health and safety and general accident prevention. Most fieldbusses have tried to address this problem area. A new international standard, IEC 61508, provides a method for implementing safety related functionality using electronic and programmable technology. The standard introduces so called Safety Integrity levels which describe the probability of a dangerous equipment or system failure. Failures, of course, cannot be avoided. But failures which allow or cause potentially dangerous situations to develop must be reduced to a level which is as low as possible. The ProfiSafe Profile that was introduced in 2000, is based on the IEC61508 standard allowing safety systems to be developed that operate using Profibus technology. Many Profibus devices are now available for factory and process automation which can be used in certified functional safety to SIL level 3, which is the requirement for many protection systems.

How does Profinet relate to Profibus? Profibus is one of a number of Industrial Ethernet technologies that has been introduced to give robust and reliable control over Ethernet. Profinet is actually totally standard Ethernet at the physical and basic protocol levels, but it uses a clever solution based on high priority messages to achieve real time operation. “Real time” means that the control system responds quickly and deterministically compared to the requirements of the process. Just how deterministic is Profinet? Well Profinet determinism is about the same as Profibus. There are actually several degrees of determinism for both Profibus and Profinet systems. For basic factory automation we typically require cycle times in the order of 5 or 10ms with determinism in the order of perhaps 1ms. This can be achieved with standard Profibus DP or Profinet devices. For higher performance systems such as positioning systems, servos, robotics we need much better performance. The Profibus and Profinet specifications support so called isochronous operation, which basically means constant cycle timing with application synchronisation. So when using multi axis servos for example, all the axes are tightly synchronised to all move together at the required time. The performance of isochronous operation on Profibus and Profinet is very similar. It is possible to synchronise such systems to within less than a micro second. Quite remarkable performance, particularly over standard Ethernet! What role can Profibus play helping industry minimise its carbon footprint? This is another area that Profibus International has been busy developing. A relatively recently introduced profile called “ProfiEnergy” is specifically designed to minimise energy usage, particularly during slack or non-operational periods.

The idea is actually very simple, just to reduce energy usage by shutting down power circuits if they have not operated, or are not required for a certain time. The key with the ProfiEnergy profile is to do this in a standardised way that can be applied across manufacturers. Initially ProfiEnergy has been developed for Profinet, but it is expected that the profile will be extended to Profibus. Profinet, which is based on Ethernet, is not compatible with Profibus. What about compatibility? You are partially correct; a Profibus device cannot be connected to an Ethernet cable. However, Profinet is compatible with Profibus. Firstly, the interface to Profibus is defined within the Profinet standard. In fact, the Profibus spec is embedded within Profinet. So, it is quite possible to run existing Profibus installations from Profinet controllers by using a standard gateway. Secondly, most of the application profiles that were developed for Profibus transport to Profinet without change, or perhaps with just minor tweaking. For example, the profiles for drives, encoders and ProfiSafe can all operate on either Profinet or Profibus. For these reasons, the investment in Profibus is protected, even if you want to introduce Profinet control in the future. Will Profinet overtake Profibus and totally replace it? True, Profinet runs at 100Mbit/s and Profibus at 12Mbit/s. But actually, the speed of the two is about the same, because Profinet telegrams are significantly longer than Profibus telegrams. For a given number of devices and data throughput, the cycle time on Profibus and Profinet is about the same. Verwer Training & Consultancy www.verwertraining.com Profibus Association of Australia 02 9555 7899 www.profibusaustralia.com.au SEPTEMBER 2011 www.pacetoday.com.au 13

IN FOCUS

Protection for helical geared motors A unique coating made of polyurethane resin mixed with stainless steel ensures maximum life expectancy from helical geared motors, writes Tony Sculpher.

ORD Drivesystems AU recently introduced the NORD Severe Duty (NSD) and NORD Severe Duty Extreme (NSDx3) enhanced corrosion protection coatings to Australia. Mark Alexander, sales director for NORD Drivesystems AU, said: “The NSD coatings have been marketed by NORD Gear Corporation in the US since 2002. Australia is the very first market outside the US to include the NSD coatings as an option for the expansive NORD Helical geared motor product range.” The coatings are not a conventional paint, but consists of polyurethane resin mixed with 316 stainless steel. This formulation is blended and supplied exclusively to NORD Gear Corporation. The polyurethane and stainless steel mix forms a low sheen metallic grey colour and is very hard when completely cured. The NSD coatings claim a high degree of exterior durability and corrosion resistance. The coatings can resist scratching and chipping unlike other conventional surface coatings such as two pack epoxy

14 www.pacetoday.com.au SEPTEMBER 2011

CHEAPER: NSD coatings offer the protection of stainless steel at a low cost.

paint. Compared to acrylic paint, the NSD coatings have 40 per cent higher impact resistance and twice the surface hardness and corrosion resistance. These coatings will also stand up to heat and

humidity. The coatings claim to offer superior chemical resistance when exposed to aggressive industrial solvents such as lacquer thinners, acetone, gasoline fuel, Xylol, lubricants and cutting

oils. The coatings are USDA H1 approved, and are suitable for almost all food manufacturing plants in Australia. Other applications include areas involving chemical wash down and corrosive environments. The coatings can withstand high exposure to water, wastewater, marine environments including salt water, chemicals and acids. There is no adverse impact on NORD Helical geared motors’ load capacity, life and performance when protected with the NSD coatings. The coatings are AS/NZS4020 compliant, and will enhance the lifespan of the Helical geared motor by completely protecting the outer surface, whilst preventing the ingress of harmful contaminants. “The big advantage to NORD Drivesystems’ customers using the NSD coatings is that they offer the protection of stainless steel at a fraction of the cost of a complete stainless steel component. Combined with NORD’s specialised extreme environment options,” said Alexander. NORD Drivesystems AU 1300 006 673 www.nord.com.au

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AIMEX PREVIEW

Plenty to see at AIMEX 2011 Asia-Pacific’s International Mining Exhibition 6-9 September 2011 Sydney Showground, Homebush

he strong mining sector continues to offer major opportunities for process control and automation products and service providers and system integrators. AIMEX 2011 will have more than 550 exhibitors and is a unique gathering in a single location of mining products and services from around Australia and throughout the world. Each day of the show, frontline mine personnel will go into a draw to win an Apple iPad 2, and will be offered the opportunity to attend special presentations and networking events. The AIMEX Women in Mining Day will be held on September 7, and will include special presentations and a networking event for all women in the mining sector. Below is a selection of products that will be at the show. www.aimex.com.au

Non-invasive belt monitoring

Collision warning

Conveyor Belt Monitoring will showcase two new non-invasive conveyor belt monitoring products. Both are designed to extend the safe working life of conveyor belting and maximise the return on assets. Headlining the display will be CBM’s Longitudinal Rip Detection System which is non-contact, has nothing embedded in the belt and works with belt types such as steel cord, fabric and solid woven. Supporting the system will be CBM’s new Vision/Profile Monitor. This system allows for visual inspection and cover thickness to be determined without stopping the belt and therefore it does not impact negatively on production.

Mine Radio Systems (MRS) will showcase a cost-effective and robust technology for collision avoidance, monitoring and reporting. The MRS Solarian Collision Prevention Solution uses transponders to collect vital tracking information, then alerts personnel and vehicle drivers of approaching dangers with audible and visual alarms. An adjustable detection range and real-time reporting capabilities enhance the system’s appeal. The Solarian system can be integrated with other MRS communication systems or can be deployed as a standalone unit. It can be easily installed or relocated.

Conveyor Belt Monitoring 02 9979 6644 jonathan.krane@cbmi.com.au

Mine Radio Systems (Pacific) 03 6427 2722 australia@mineradio.com

Logic blocks and valves

Classification and screening

Hydraulic Controls will release its latest manually operated roof bolter and rib bolter logic blocks, hydraulic integrated circuits and a new stainlesssteel water valve for mining applications. The logic blocks are designed to work with various drill rigs that install roof and rib support bolts. They are manufactured to the Mining Design Guideline (MDG) specifications covering bolting and drilling equipment in mines. The company will also feature its locally made hydraulic integrated circuits, made to specifications determined by the customer and Hydraulic Controls. Another feature of the company’s stand will be its stainlesssteel water valves designed to control the flow of cooling or flushing water in hostile mining environments. The valves can pilot operate to start or stop water flow and are also fitted with a bypass valve for manual operation.

Ludowici will showcase a range of new minerals processing equipment. Spearheading the display will be its patented RC2020 Reflux Classifier for cleaning fine coal and minerals and which, according to Ludowici, is set to revolutionise the global mining industry. The classifier, which can separate particles by either density or size, was developed through a joint venture between Ludowici and the University of Newcastle. It combines three technologies: a Lamella settler, an autogenous dense medium separator and a fluidised bed separator. The RC2020 is said to be an ideal alternative to spiral technology – but with a footprint up to six times smaller than spiral systems. It is also estimated to provide a 10% increase in raw material recovery and was recognised by the IChemE2010 Awards in the UK, winning the Core Chemical Engineering category for maximising resource efficiency.

Hydraulic Controls 02 9938 5400 paul@hydrauliccontrols.com.au

Ludowici Australia 07 3121 2900 enquiry@ludowici.com.au

Thermal imaging camera is dust and splash proof FLIR Systems will unveil an infrared camera for identifying leaks of potent greenhouse gases. The GasFindIR LW camera can deliver real-time thermal images of gases such as sulfur hexafluoride (SF6), which is used to prevent arcing in high-voltage circuit breakers and gas-insulated substation equipment. If SF6 leaks into the atmosphere 18 www.pacetoday.com.au SEPTEMBER 2011

from faulty or aging equipment, it can contribute to global warming. The Intergovernmental Panel on Climate Change has described SF6 as the most potent greenhouse gas it has evaluated. The camera is designed to locate the smallest of leaks in hot, cold and normal environments. FLIR Systems Australia 03 9550 2800 info@flir.com.au

Portable oscilloscopes

Advanced drill management Automated Positioning Systems (APS) will unveil a new drill guidance and management system, mineAPS Drill. This is the companyâ&#x20AC;&#x2122;s most advanced drill guidance and management solution to date for rotary blast hole and hydraulic rock drills. Using sophisticated GNSS technologies, mineAPS Drill removes the need to mark out a drilling pattern, reducing time and costs while also extending operations in poor weather or lighting conditions. mineAPS Drill can also recognise hazards such as old workings and high walls to improve operator awareness and autonomy. An updated operator interface and data sharing between multiple rigs working the same pattern are among the new features of mineAPS Drill. Automated Positioning Systems 07 3277 2100 sean.frendin@apsmining.com

Fluke Australia will showcase the worldâ&#x20AC;&#x2122;s first portable four-channel oscilloscopes engineered for harsh environments. The Fluke ScopeMeter 190 Series 11 handheld scopes feature four input channels which are fully isolated from each other to undertake differential floating measurements, a critical consideration for trouble shooting fixed installation three-phase power electronic devices. They are also designed to test inverter power electronic technology used in green energy generation and transportation applications. The scopes are safety rated for Cat III 1000V/Cat IV 600V environments.

Energy efficient Mining Drive

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

SEW-Eurodrive will release an important addition to its industrial gear unit range. The new Mining Drive is a large gear unit in a purpose-designed thermal housing, that will make a significant reduction to energy usage through the lessening of thermal losses. Heavy industry requires machinery with more torque and power, requiring larger amounts of energy. The Mining Drive will drive down heat losses and reduce overall energy consumption. SEW-Eurodrive 08 9251 4900 www.sew-eurodrive.com.au

Self-drilling injection bolt for underground mining Minova International will feature its NovoBolt self-drilling injection bolt and Carbomine phenolic resin injection system suitable for underground mining. The Carbomine system, which was developed specifically for Australian underground coal mining, is described as an ultra safe NSW D11-approved injection resin that is fully LOBAcompliant. Minova will also preview its Carbothix resin

grouting system at AIMEX. This bolt anchorage and encapsulation system can be used with the NovoBolt or several cable bolt products to ensure full encapsulation and rapid pre-tensioning. A large range of steel rock bolting products and Lokset resin capsules, Secura bolts, Carbofill and Ventilation-on-Demand products will also be featured. Minova International 02 4428 5248 matthew.berry@minovaint.com

Jigsaw technology Leica Geosystems will launch the second generation of its Jigsaw mine management system which claims to represent the industryâ&#x20AC;&#x2122;s first fully integrated hardware and software platform which seamlessly links three key levels of mining operations: fleet management, product optimisation and highprecision guidance. The company builds technology solutions that allow mines to maximise every aspect of their operations - solutions that integrate information and control across all equipment no matter what type or which manufacturer. Leica Geosystems Mining 07 3117 8977 stefana.vella@leica-geosystems.com SEPTEMBER 2011 www.pacetoday.com.au 19

IN FOCUS

How to enhance your process insight Advanced Diagnostics embedded in a pressure transmitter can proactively detect abnormal process conditions,

RESSURE transmitters measure pressure, flow, or level and may be used to control or monitor changes in a process. Although plants make every effort to instrument and control their process effectively, there may be abnormal conditions that could cause a loss of production, plant shut-down or safety hazard. Rosemount 3051S Advanced Pressure Diagnostics technology provides a means for early detection of abnormal situations in a process environment. This technology can also detect integrity issues in the electrical loop that connects the transmitter to the host system. Advanced Diagnostics technology enables the user to proactively respond to changes in the process, troubleshoot, and prevent future shutdowns.

Process Noise

Standard Deviation

Process Intelligence Virtually all dynamic processes have a unique noise or variation signature when operating normally. Changes in the signatures may signal that an abnormal event has occurred or will occur soon. Examples of abnormal events that are detectable using SNAPSHOT

Process Variable (PV)

SMP TECHNOLOGY Statistical Process Monitoring provides the means to detect abnormal process conditions within the limitations of typical control systems and process historians. A smart pressure transmitter measures the pressure and calculates statistical parameters at a high speed allowing it to monitor the process noise prior to any analogue or control system damping. Statistical parameters (mean, standard deviation, coefficient of variation) are computed within the transmitterâ&#x20AC;&#x2122;s microprocessor and sent to the host system via HART or Foundation Fieldbus. These parameters are then used to determine the presence of an abnormal condition.

20 www.pacetoday.com.au SEPTEMBER 2011

Time (minutes)

FIGURE 1: Effect of changing noise levels on the mean and standard deviation values for a process signal.

process variation include plugged impulse lines, furnace flame instability, distillation column flooding, pump cavitation, and entrained gas in liquid flow measurements. Since pressure measurement applications require a very stable reading, damping is typically applied to both the transmitter and the host system to reduce or eliminate variation. Most

control systems sample the pressure once per second or slower and process historians may sample the process variable as slow as once per minute. By the time the pressure measurement reaches the control system most of the noise and variation characteristics have been filtered out, making it difficult or impossible to detect these abnormal process conditions.

Figure 1 shows one example of how the Standard Deviation value is affected by changes in Process Noise while the Process Variable (PV), as typically seen by the control system, remains unchanged. Figure 2 illustrates Statistical Process Monitoring technology in greater detail. The process pressure is measured by the pressure sensor, and sent to the host

IN FOCUS

write Erik Mathiason and John Miller.

Since pressure measurement applications require a very stable reading damping is typically applied to both the transmitter and the host system to reduce or eliminate variation.

FIGURE 2: Pressure Transmitter implementing Statistical Process Monitoring technology.

system via 4-20 mA, just as with any other typical pressure measurement. At the same time, a Statistical

Calculations Module computes the mean, standard deviation, and coefficient of variation (CV).

Host system The Statistical Parameters (or SPM variable) are made available as outputs to the host system as HART or Foundation Fieldbus digital variables, where they may be trended in a process historian and viewed by a plant operator. If a process upset occurs, plant staff can look at the process historian and examine the Statistical Process Monitoring (SPM) variables to determine if changes in these values gave any prior indication. After understanding how changes >

FIGURE 3: Simplified View of the Statistical Process Monitoring technology. SEPTEMBER 2011 www.pacetoday.com.au 21

IN FOCUS

in the SPM variables are affected by process conditions a control engineer can create DCS alerts or alarms based on the SPM data. Alternatively, one may utilise intelligence resident in the pressure transmitter to detect abnormal process conditions. The Learning Module of SPM technology learns the operating conditions and statistical patterns (Baseline Values for Mean, Standard Deviation, and CV) when the process is operating normally. The Decision Module compares the current statistical values against the baseline values and detects an abnormal event if the current value deviates from the baseline value by more than some limit. The host system is notified of this detection either via device alert (HART or Foundation Fieldbus) or analogue alarm (HART only). Figure 3 illustrates in more detail how the Learning and Decision intelligence of SPM technology works. There are two primary modes: the Learning/Verifying mode (performed in the Learning Module) and the Monitoring mode (performed in the Decision Module). During the Learning/Verifying mode, the mean and standard deviation are computed over a user-configurable length of time (default is three minutes). First, the module determines if there is sufficient process variation to perform the SPM diagnostic. If there is not enough variation it gives the message â&#x20AC;&#x153;Insufficient Dynamicsâ&#x20AC;?. If there is enough variation, then the SPM computes mean and standard deviation over the next three minutes to determine if the process is stable. If the process is stable, the SPM takes the current statistical values to be the baseline values and moves into the Monitoring mode. If the process is not stable, the SPM remains in the Verifying mode. This stability check is an important part of the SPM technology because if the transmitter learns the baseline values while the process is not stable there is a much greater chance of generating a false detection during the Monitoring phase. In the Monitoring phase, the SPM again checks to see if the system is stable (that is, if the pressure value is near its baseline). If the mean pressure has changed significantly, the SPM goes back into the learning mode. If the system is stable, then the SPM 22 www.pacetoday.com.au SEPTEMBER 2011

Field test and laboratory data have shown that for most DP flow applications the standard deviation is approximately proportionate to the DP mean.

FIGURE 4: SPM Abnormal Event Detection visible in AMS Device Manger.

FIGURE 5: Standard Deviation vs. Coefficient of Variation with Changing Flow Rates.

checks if the process dynamics (standard deviation or CV) have increased or decreased significantly. If so, either a High Variation Detected or Low Variation Detected alert is generated. Electronic Device Description Language (EDDL) and FDT/DTM technologies allow advanced pressure diagnostics to be utilised in any host system environment that support one of these standards. Figure 4 shows an example of Statistical Process Monitoring technology in AMS Suite: Intelligent Device Manager. When the process was operating normally, the standard deviation (red) is

near the baseline (blue). When an impulse line is plugged, the standard deviation decreases below the lower threshold (gray) and a Low Variation alert is triggered. At the same time the mean (which follows the pressure value) remains unchanged.

Coefficient of Variation In DP flow applications, the standard deviation is affected by the Differential Pressure. Thus, if the flow rate increases, the standard deviation also increases. If the flow decreases, the standard deviation decreases.

A change in standard deviation caused by a changing flow rate should not be interpreted as an abnormal event. SPM has the ability to relearn new baseline operating conditions if the mean changes significantly, which can reduce the possibility of a false detection if the flow rate changes. However, field test and laboratory data have shown that for most DP flow applications, the standard deviation is approximately proportionate to the DP mean. This relationship has been observed in a variety of fluids (e.g. liquid and gas), primary elements (orifice plate, venturi, flow nozzle, Annubar, etc.) and beta ratios. The ratio of standard deviation to mean is defined as the Coefficient of Variation (CV). CV = (StDev/Mean) x 100% CV will remain approximately constant even if the flow rate changes. Thus, if an operator observes a change in CV, it is much less likely due to a change in the flow rate, and much more likely due to the presence of some abnormal process condition. The newest pressure transmitters with Advanced Diagnostics and Statistical Process Monitoring provide CV directly as a HART digital variable and can generate alerts if the CV changes from baseline conditions. Figure 5 shows a comparison of standard deviation with CV. During the abnormal event (e.g. plugged impulse line, entrained air, etc.) both the standard deviation and the CV increase. But when the flow rate is increased, the standard deviation increased while the CV stayed generally constant. Note that CV is recommended to be used only with DP flow applications, because for other pressure applications (e.g. line, absolute, DP level) the relationship of standard deviation being proportionate to pressure > does not hold.

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IN FOCUS

Diagnostic Applications Within every process there are many abnormal situations that can result in an untimely plant shutdown or loss in productivity. Over 20 different applications have been identified as being detectable using Statistical Process Monitoring technology. One example application is detection of plugged impulse lines. In many instances pressure transmitters are installed with impulse piping that can become plugged with solids or frozen in cold environments. Figure 6 shows common examples of causes of plugged impulse lines. The user typically has no idea that this has occurred because the pressure is effectively trapped between the plug and the transmitter, resulting in the pressure measurement not responding to changes in the process. The trapped pressure causes a change in the process noise, which can be seen by the SPM technology and can be used to detect plugging in either one or both impulse lines. Using SPM technology to detect impulse line plugging may

FIGURE 6: Shows a plugged impulse line and several plugging methods that could cause this condition.

increase the Safe Failure Fraction and safety rating of the measurement point. Another application of the SPM technology is detecting the instability of

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FIGURE 7: This is an example of Furnace Flame Instability under actual factory conditions.

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furnace flames. In many pieces of fired equipment NOx emission standards are met by multi-stage burner design and exhaust gas recirculation. Either technique tends to give a burner design with a much narrower stable operating window, thus making flameouts more likely. Rather than detecting flameout after it has occurred SPM can detect an incipient flameout. This makes it possible to proactively detect the instability and prevent the flameout. The example in Figure 7 shows how the process noise (Standard Deviation) registers instability in the furnace flame on all three of the transmitters monitoring this furnace, while the primary variable (draft pressure)

measurement does not register any change in the process. In conclusion, Advanced Diagnostics embedded in a Rosemount 3051S Pressure Transmitter can provide a means for early detection of abnormal conditions in a process environment. Using this technology enables the user to proactively respond to changes in the process, troubleshoot, and prevent future shutdowns. [Erik Mathiason is Marketing Engineer, Pressure Diagnostics and John Miller is Principal Engineer, Pressure Technology both from Emerson Process Management.] Emerson Process Management 1300 553 051 Rosemount.com/3051SDiagnostics

Memosens connecting partners Memosens bridges the gap Memosens digital sensor technology bridges the gap in analytical measurement. It solves the problems of moisture ingress, leakage and corrosion with inductive, contactless sensor-cable connections. Reliable, interference-free data transmission â&#x20AC;&#x201C; and most importantly, process safety â&#x20AC;&#x201C; is guaranteed. Plus its robust transmission signal removes the need for pre-amplification or expensive cabling. And its digital memory stores calibration data for true plug-and-play capability. Now there are Memosens sensors covering most analytical process control and asset management systems. The gap in analytical measuring is finally closed. Endress+Hauser Australia Pty Ltd Unit 8, 277 Lane Cove Road North RydeLink Business Park NORTH RYDE NSW 2113

Phone +61 2 8877 7000 Fax +61 2 8877 7099 info@au.endress.com www.au.endress.com

BEHIND THE SCENES

CMS keeps Xstrata hauling Condition monitoring is a simple and effective tool that prevents major failure, writes Luke Brand.

STRATA’s site in Cloncurry has been able to reduce downtime and prevent expensive machine failure through the use of Komatsu’s Conditioning Monitoring Service (CMS) on their haul truck fleet. The 18 Komatsu trucks on-site are unique, running the only 36:1 electric wheel motors in Australia. Careful monitoring of the performance and condition of these motors is of significant importance to Xstrata, with potential repair costs exceeding $250,000, according to Alf Bonato, Komatsu’s Technical Representative for the site. “Xstrata were first introduced to

26 www.pacetoday.com.au SEPTEMBER 2011

CMS as part of their Maintenance and Repair Contract, initiated when the machines were delivered. “The 787 wheels motors have a relatively small oil pick-up area and small oil storage compartment, and with few replacement gear-sets available anywhere in the world, minimising the risk of significant and costly downtime was priority number-one,” he said. Xstrata mine maintenance planner Kari Markham said that with the fleet now passing 65,000 hours each, CMS has played an important role in maintaining production at the site. “With a pit depth in excess of 600 metres, the trucks move overburden and ore along a steep incline, meaning exten-

LABORATORIES: Technicians are trained to screen and analyse the performance of oils.

sive monitoring is required to prevent overheating issues. “By knowing what’s going on (mechanically) with each truck, we can

provide feedback to the production department, and initiate additional education of drivers if needed,” he said. Markham commented that with the contract now complete, Xstrata has continued to utilise CMS – drawing upon more than eight years of component history to continue monitoring wheel motor condition and schedule maintenance. “CMS is a simple and effective tool that not only prevents major failure, but allows for accurate maintenance planning with knowledge of upcoming problem components,” he said. Komatsu 1300 566 287 www.komatsu.com.au

| BS11-02E |

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

IPC Industrial PCs Embedded PCs Motherboards

I/O EtherCAT components IP 20 Bus Terminals IP 67 Fieldbus Box

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

Automation Software PLC Software NC/CNC Safety

SPOTLIGHT

7best of the

Uninterruptible Power Supplies for the industrial market Designed specifically for the industrial market, the Bulletin 1609 UPS family includes three distinct series to meet application requirements up to 10 kVA. The U and S series provide surge and filter functions in addition to bridging dips, sags and brief power losses to help ensure operational efficiency. These UPSs have DIN rail and panel mount capabilities, optional 50°C battery and hardwired input/output connections. The U and P units include network management and communications capabilities such as Ethernet and RS232 to monitor and control a range of devices. In addition, devices can also be controlled via optional dry contact I/O communication cables. The units can communicate battery status to PLCs via integrated dry contacts. To prevent downtime and equipment damage due to power outages, voltage fluctuations and transient surges, the units have a line interactive design with pure sine wave output. Rockwell Automation 03 9896 0300 www.rockwellautomation.com.au

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

Regulators offer accurate pressure control Swagelok RHPS series general industrial regulators offer accurate pressure control of pressures from 0 to 400 bar in gas and liquid systems, 1/2 to 2 inch sizes. RS and RSH model regulators employ either a spring-loaded diaphragm or piston as the sensing element, depending on the outlet pressure range desired. The RS model is available with a choice of six outlet ranges; from 0 to 3 bar up to 0 to 350 bar. The RSH model is available with a choice of nine outlet ranges; from 0 to 3 bar up to 0 to 700 bar. The LPRS model regulator, with larger diaphragm, offers tight control of low pressures spanning 0.1 to 3 bar, making it ideal for applications requiring a second regulator for twostage reduction of pressure. Temperature range for all models is -20° to 80°C. Standard material of construction for regulator body and spring housing is 316L stainless steel. Seal, O-ring, seat, and diaphragm material choices are nitrile, ethylene propylene, PTFE, and fluorocarbon FKM. Seat material

choices also include PCTFE and PEEK. Swagelok 08 8369 0899 www.swagelok.com

Calibrating sieves made simpler Sieve accuracy can now be checked in house using a simple weighing technique which is both fast and low cost. This method provides verification using microsphere standards. These sieve standards cover every sieve between 20 and 3,350 μm. The procedure may be completed in two minutes and is traceable to international standards – NIST, NPL. The single-shot vials remove operator sampling errors and are accurate to 1 μm for the smaller apertures sieves. This method analyses over 80% of the sieve surface. The calibration of test sieves has been further simplified with new software. It allows the calculation of sieve apertures directly from the weight of glass calibration beads passing through the sieve. To determine the mean aperture size, the operator simply selects the nominal rating of the sieve to be calibrated and enters the initial weight and the weight of the beads passing through. The new program is provided free to customers purchasing Sieve Standards. ATA Scientific 02 95413500 enquiries@atascientific.com.au 28 www.pacetoday.com.au SEPTEMBER 2011

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

Pneumatic diaphragm valve from Georg Fischer Because this valve series has the highest closing force, it is implemented wherever high line pressure, up to 10 bar on both sides, needs to be controlled. The DIASTAR 025, with the integrated accessory interface, enables easy system integration. Available in the failsafe-to-close (FC); fail-safe-to-open (FO) and double acting (DA) modes of operation. The DIASTAR 025 is used in chemical dosing; control of pure and ultrapure media and in applications with higher viscosity and solids content. Georg Fischer 02 9502 8000 www.georgfischer.com.au

Stainless steel rope-pull switch IDEM have added grade 316 stainless steel ropepull switches to their ‘Next Generation’ range of safety interlock switches. These IP67 units will be suitable in wet washdown locations such as food and beverage, as well as mining applications subject to harsh treatment and corrosive atmospheres. The GLH rope-pull safety switches come standard with a tension gauge and special quick-fit cable clamps to simplify setup. They can also be fitted with: E-Stop button; High-visibility status LED or

Power quality analyser

IDESAFE two-wire network for reduced cabling, saving time and costs. The IDESAFE network safety solution is suitable for long bulk material conveyors in mining, quarries, tunnels and mineral processing plants. IDEM also provide Stainless Steel E-Stop, tongue and non-contact safety interlock switches. DAANET 1300 322 638 www.daanet.com.au/idem

Tube bundle gas monitoring

The Fluke 434/PWR Power Quality Analyser helps engineers and technicians uncover energy waste in commercial and factory buildings as well as in equipment and machines. The 434/PWR can be used to conduct energy consumption studies and electrical load analysis, and to perform power quality logging and analysis surveys. The power analyser can also help technicians demonstrate the benefits of efficiency improvements by testing energy consumption. The instrument measures harmonic distortion caused by electronic loads, and analyses reliability problems by capturing voltage dips and swells from load switching. A full-colour display uses industry-standard, user-selectable colour coding to correlate measurements with actual wiring. It logs incoming data with an AutoTrend function that highlights changes of data over time. The data can then be analysed with Fluke’s Power Log software, which is included with the 434/PWR.

The comprehensive Gas Monitoring Systems from Australian Dynamic Technologies (ADT) provide early warning of pending problems in gassy coal mines, with continuous scanning of multi tubes running underground and bringing samples to the surface for analysis of methane, carbon dioxide, carbon monoxide, oxygen and hydrocarbons. The system is controlled by newly developed CMTS SmartGas-connect MineGas2 Software with 10, 20, 30 or 40 sampling points covering most coal mine applications, using ultra fast gas sample response times over distances up to 15 km, with all equipment conforming to Australian Standards. Gassy coal mines will benefit from the accurate and reliable gas measurements and alarms to prevent underground disasters, as has happened recently. An ADT system would have alerted a group of engineers to take immediate steps by removing workers from underground before an ignition could occur.

Fluke Australia 02 8850 3333 www.fluke.com.au

Australian Dynamic Technologies 02 4577 9347 www.austdynatech.com.au SEPTEMBER 2011 www.pacetoday.com.au 29

EVENTS & EDUCATION

WHAT’S ON

REVIEW

International Desalination Association World Congress 4-9 September 2011, Perth www.idadesal.org AIMEX 6-9 September 2011, Sydney www.aimex.com.au Grounding & Noise Reduction 15 September 2011, Adelaide www.iica.org.au EMO Haannover 2011 19-24 September 2011, Germany www.emo-hannover.de Safety Control & Instrumentation Systems 20-22 September 2011, Perth www.iica.org.au Functional Safety Demystified 29 September 2011, Webinar www.icheme.org

Maintenance and Reliability Best Practices ‘Maintenance and Reliability Best Practices’ By Ramesh Gulati & Ricky Smith Industrial Press $62.95 This 416-page book is a practical resource designed to help seasoned professionals and novices understand the basic principles of maintenance and reliability. It is written by professionals with 60-plus years of shop floor and management experience in a variety of industries. Written in an easy-to-read format, each chapter discusses the concepts with specific questions and answers. Each topic

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answers the what, why or how of the topic being presented. Understanding and implementing maintenance and reliability practices in a cost-effective way is essential.

‘Benchmarking Best Practices in Maintenance Management’ By Terry Wiremann Industrial Press $62.95 Thoroughly revised and updated, this best selling book presents a logical, stepby-step methodology that will enable any company to conduct a cost-effective benchmarking effort. It presents an overview of the benchmarking process, a detailed form for surveying and grading maintenance management, and a database of the results of more than 100 companies that have used

this survey. The book provides a concise benchmarking methodology and explains the most current maintenance benchmarks. It contains a benchmarking database from more than 100 companies and features current maintenance/ asset management philosophies.

You could win one of these books by answering the following question: On which page of this magazine will you find “IEC 61508” mentioned? Email your answer to kevin.gomez@reedbusiness.com.au

Both books are available direct from Elsevier Australia Customer Service, 1800 263 951 or customerserviceau@elsevier.com

IICA NEWS & VIEWS

Understand and benefit from the IICA The IICA focuses on education, standards and networking, writes Brett Simpson. THE Institute of Instrumentation, Control and Automation Australia (IICA), in welcoming the recent partnership agreement with PACE magazine, wishes to take this opportunity to acquaint PACE readers – especially those who are not IICA members – with an overview of who we are and what we do. We are a not-for-profit professional Institute of Individual and Corporate Members from a diverse range of industries, academia and manufacturing. Our Members include end users, suppliers, consultants, contractors, apprentices, academics and students, working in the instrumentation, control systems and automation fields of activities. Our Institute rests on three core planks or areas of professional interest – Education, Standards and Networking. 30 www.pacetoday.com.au SEPTEMBER 2011

Under the Education banner, the IICA offers regular nation-wide Professional Development Training Courses in every state; provision for developing standardised in-house training; access to the internationally recognised ISA professional qualifications of Certified Automation Professional (CAP) and Certified Control Systems Technician (CCST). Last but definitely not least the IICA produces nationally co-ordinated Seminars on topics of relevance. Standards embraces a wide range of activities aimed at raising the professionalism of persons and companies engaged in our areas of interest. Examples include: • Involvement in Australian and International Standards setting

Committees • Advocacy for increasing instrumentation and control systems contents in Australian university and TAFE engineering courses • Lobbying for recognition of instrumentation and electrical as two separate qualifications, where persons study the dual- trade electrical/instrumentation TAFE courses. • Raising the professionalism and lifting current operating benchmark standards in sections of airline maintenance sectors-civil and defence. IICA in collaboration with RMIT University and the AAAAI is working to produce tailored technical courses and instigate a formal Registration system for presentation to both CASA and Defence for support and endorsement.

Finally, we come to the Networking link in the IICA education, standards and networking triangle. Networking in the IICA context means communication between like-minded professionals. This can be during the nation-wide Technology Expos in both capital cities and regional areas; via the LinkedIn networking vehicle that the Institute has embraced, or via the face-to-face Branch Meetings – technical as well as social. The IICA also helps bring together individuals and corporate entities from across the wide spectrum of the supply chain – from manufacturers and suppliers to end users, as well as all the other players in between. [Brett Simpson is IICA Federal President.] www.iica.org.au

Because we offer custom assemblies, we’re able to tailor our products to give your company exactly what it needs. It might be as simple as a

Now assembling products your way.

routine assembly, or as comprehensive as an engineered, assembled and tested ﬂuid system. Our drive to deliver on Innovation is why we’ve invested so many resources into helping our associates understand a wide variety of applications. So with Swagelok Custom Solutions assemblies, ®

everything’s coming together. Visit swagelok.com/customsolutions.

You’ll love what we’ve done with your calibrator. The NEW Fluke 754 lets you do the work of several tools. Calibrate temperature, pressure, voltage, current, resistance and frequency. Easily troubleshoot HART instrumentation, not to mention record and document your results. All this plus a brighter screen, newer software, improved battery life, USB port, and improved accuracy with a 99.6 % conﬁdence level. Fluke process calibrators: Work smarter. Work faster.

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

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