What’s New in Process Technology Apr 2012 by Westwick-Farrow Media

0412

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY APRIL 2012

WeidmĂźller has released its new IES series

CONTENTS

of Industrial Ethernet switches to supersede its existing range. Reliable, sophisticated and functional, the new series has been designed to meet the increasingly complex and demanding tasks of monitoring and controlling operational data.

The DNP3 protocol dvantages for water and wastewater A

With three ranges to choose from, the series

telemetry systems

Gigabit Ethernet managed switches with

New products

Hot products online

Clever pumping rive modules specially designed for D

offers a broad choice of Fast Ethernet or various port combinations. Users can select from the entry level IES21 Fast Ethernet or the IES31 Fast Ethernet with Gigabit Uplink, up to the IES41 full Gigabit Ethernet switches. Offerring a broad range of functionality, the switches feature ring redundancy with floating

pumping applications.

Redundancy in industrial networks

master, the latest security features, IGMP

Part 2

As I see it National OHS harmonisation: Will it arrive?

snooping and a built-in virtual cable tester. Suitable for use in the factory, automotive process and oil, gas and renewable energy industries, the family meets all current Australian standards. It delivers exceptional performance and reliability, thanks to a range of advanced features. Equipped with the all-new W-Ring technology, the IES family delivers far more redundancy and greater reliability than previously. W-Ring simplifies network requirements by eliminating master/slave settings in a redundant ring, while providing a network reinstatement time of less than 20 ms. The switches can be operated in harsh and demanding environments and have been created to withstand operating temperatures up to 85ÂşC as well as excessive vibration. Housed in robust metal casings with no need for fans or case venting, the family is IP40 protected. Highly compact, the switches can be DIN rail- or wall-mounted.

NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.

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Weidmuller Pty Ltd www.weidmuller.com.au

THE DNP3 PROTOCOL Vishal Prakash

ADVANTAGES FOR WATER AND WASTEWATER TELEMETRY SYSTEMS

ÂŠ iStockphoto.com/Bart Sadowski

DNP3, or Distributed Network Protocol, has been around for close to two decades now. It was developed by Westronic in 1993, primarily for the power industry.

4 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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rom its inception, DNP3 has been an open protocol, allowing end users to use a common protocol across many hardware platforms. It has a number of features and advantages, however, the features described below are particularly useful for water and wastewater applications.

Open protocol The guardian of the DNP3 protocol is the DNP3 Users Group Technical Committee, which was formed in 1995 and is vendor independent. The committee’s charter not only includes specifying protocol enhancements and new functionality called 'DNP Subset Definitions,' but ensures there is backward compatibility and absolutely makes sure there are no vendor specific variants of the protocol. The firm compliance requirement ensures that hardware and software manufacturers who do support DNP3 do so within very well defined parameters. It should be noted that a vendor need not support all DNP3 protocol functionality. The compliance to DNP3 can be via three different levels - 1, 2 and 3. All vendors who support DNP3 must make available a device profile document that clearly lists the DNP3 features supported by the product and thus the compliance level.

Classification of field data In a water or wastewater system there are various assets that require monitoring and control. These include treatment plants, pump stations, valve sites, canals, weirs, tanks, ponds, dams, reservoirs, pipelines and much more. At these locations, a great deal of normal day-to-day activity exists. For example, at a pump station, it is very normal for the pump to go ON or OFF when the configured conditions are true or false. The question is - do you want every event reported to the top end? The answer is no, because this will take up bandwidth and, possibly, prevent information on critical events from getting through to the DNP3 master device. To prevent this scenario, DNP3 protocol allows users to classify their data into

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different groups called ‘class’. The protocol currently supports four classes of data - 0, 1, 2 and 3. Class 0 data is real-time data. Classes 1, 2 and are reserved for objects that require timestamp information (event data). Each class of data is independent from the other. A class of data also has variation parameters which allow the user to select the type of value, time and diagnostic information to be recorded. This DNP3 protocol feature is extremely useful, especially in multilayered systems as it allows the user to categorise field data. For example, normal conditions at a pump station site, like pumps starting and stopping, may be configured as Class 2 type events. Thus, when the pump changes state, an event will be created as a Class 2 type event and stored in memory. Since this is normal operation, an unsolicited report (or Report by exception) need not be initiated to a DNP3 master device. When the master device performs a routine background poll, it can recover all Class 2 events. But assume at the same pump station site there is a pump fault indication. This is, in most cases, a critical alarm of which the DNP3 master needs to be aware, so that appropriate action can be taken. Thus, the pump fault status indication can be configured as a Class 1 event, thereby triggering an unsolicited report to the DNP3 master device. DNP3 protocol’s fundamental support for data classification allows the end user to design and operate an efficient telemetry system irrespective of the type of communications media being used.

Report by exception (unsolicited reporting) Report by exception refers to a remote device’s ability to initiate communications to a top-end master. Traditional telemetry systems are typically poll-only systems. In medium-to-large systems, a polling protocol can lead to loss of data. To prevent the loss of data, communications bandwidth would have to be increased constantly. Taking the example described above, with DNP3 protocol’s inherent support for

APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Telemetry

DNP3 Master

Radio Ethernet

PSTN (Modem)

PSTN Cloud

DNP3 Outstation Devices

Fiber Optic Ring

Figure 2: DNP3 Secure Authentication using dynamic keys, that are updated, automatically and periodically, between a DNP3 Master and outstation RTU.

Figure 1: An example multilayered telemetry system.

unsolicited reporting, the pump fault alarm can be sent to the DNP3 master immediately upon occurrence. If the telemetry system were a poll-only system using a different communications protocol, the alarm information would only be seen at the top-end after the outstation has been polled by the master. And even when the master sees the pump fault status indication, it will not have the event timestamp information.

Timestamped data Timestamped data is also known as eventlogged or event-based data. It is, basically, where an event such as a pump changing its status from ON to OFF, or a change in the tank level by a certain percentage within a specified time period, will be recorded in the device with a time and date stamp. Sounds simple… well, it is simple, because the DNP3 protocol specification dictates how the timestamping is to be done and which parameters are to be recorded. This standard has to be maintained by all vendors that claim to support DNP3 protocol. Having access to time-stamped data for an end user is hugely valuable: • Many telemetry systems are poll-only systems for a number of reasons geographical, or by virtue of design, which means that without timestamping, if an event occurs and the device is not polled at that instant in time, the event will be lost. Now, an event like a change of pump status can be stored as the number of times the pump has come ON and the number of times the

pump has gone to the OFF state. This is useful information, but it does not provide the time the pumps went ON and OFF. The time information is useful for analysis such as the times during the day the pumps start. • In the event of a communications failure, a device can continue to record the events and store them in memory. Once the communication system has recovered, a top-end master will be able to retrieve these events and graphically display, accurately, the events that occurred during the communications failure.

Time synchronisation The DNP3 protocol supports time synchronisation. A DNP3 outstation device can be configured to send a time sync request to the master or a DNP3 master can periodically send a time sync command to DNP3 outstation devices. Time sync is part of the DNP3 protocol specification. Key advantages of the time sync function include: • Accurate and reliable time-based alarm information from a remote device. • Scheduling accuracy - for example, when to switch over from duty to standby pump; generate test unsolicited messages at a particular time.

Secure authentication As critical infrastructure, water and wastewater systems must be secured. There have also been a few well publicised and documented instances of SCADA security

6 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

breaches that have affected the performance of the systems. The DNP3 protocol includes IEC62351 version 2 authentication. DNP3 secure authentication allows a DNP3 slave or master device to unambiguously determine if it is communicating with the correct DNP3 master or slave. In water and wastewater systems it is common to issue pump/valve (or similar) operate commands from the top-end master. Without authentication, it is completely possible for someone to intercept a message and relay with modified settings. DNP3 Secure Authentication overcomes this issue, as the DNP3 outstation challenges the DNP3 master to see if the command to operate comes from a legitimate source. The authentication key is updated regularly between a DNP3 master and outstation. This communication is separate and not part of standard DNP3 data transfer messages. If an outstation does not receive an updated key within a specified period of time, or if the key is invalid, then the control commands from the DNP3 Master, even if valid, will not be executed by the outstation device. The DNP3 protocol also uses a more basic form to ensure control commands are executed correctly. This is called 'selectbefore-operate.' In this case, a DNP3 Master will first send a 'select' command, to which the outstation device will respond, and then, if the outstation device does not receive the 'operate' command within a specified amount of time, it will not execute the control action.

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Telemetry

DNPAI0

IOPOINT_D

Class 1, 32-bit analog input (variation 1) ai object, class 1, static var. 1 (With flags), event var. 3 (With time)

DNPAI1

IOPOINT_D

Class 2, 32-bit analog input without flag (variation 3) ai object, class 2, static var. 3 (No flags), event var. 1 (No time)

DNPAI2

IOPOINT_D

Class 0, 32-bit analog input (variation 1)

DNPAO0

IOPOINT_D

Class 0, 32-bit analog output status (variation 1) analog output object, real time data point (class 0)

DNPBC0

IOPOINT_D

Class 1, 32-bit binary counter (variation 1) binary input counter

DNPBI0

IOPOINT_B

Class 1, binary input with status (variation 2) bi object, class 1, static var. 2 (Diagnostic flags), event var. 2 (With time)

DNPBI1

IOPOINT_B

Class 0, single bit binary input (variation 1)

DNPBI2

IOPOINT_B

Class 0, single bit binary input (variation 1)

DNPBO0

IOPOINT_B

Class 3, binary output (variation 1) bo object, class 3; static var. 1 (With flags); event var. 1 (No time)

DNPFC0

IOPOINT_D

Real time value (class 0), frozen counter 1

DNPFC1

IOPOINT_D

Figure 3: A DNP3 outstation device communicating with several DNP3 master devices.

Table 1: Various DNP3 objects and their different classifications — 0, 1, 2 and 3.

Diagnostic information for each I/O point

Advanced communications features for DNP3-based telemetry systems

Another inherent feature of the DNP3 protocol is associating diagnostic information for each field object - whether it’s pump status, tank level, current flow rate, etc. The diagnostic information answers questions such as, is the point online or offline, was it locally forced, chatter-detected, has it been restarted, is the value out of range and much more. Again, in typical systems, a status indication for a pump will only show it is ON or OFF, in FAULT, or OK. But when using DNP3 protocol, one can detect if the information regarding the status of the pump is coming from the correct location. This is useful because, remotely, one can tell if wiring is correct. Another example is if the chatter filter bit is SET, then if a field device is going ON/OFF continuously, spurious event logs will not be created.

Communication to multiple masters This is a particularly useful feature, especially in water and wastewater systems, since it is typical for a water or wastewater telemetry system to be spread over large areas. This is especially true in countries like the US, Australia, China and Brazil. When systems are spread over a large area, it is important for the local operators of the telemetry system to know what is happening, as it will allow them to respond quickly. At the same time, the same data needs to be made available at the system-wide, top-end DNP3 master.

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As stated above, one of the cornerstones of DNP3 protocol is that it is an open protocol with no vendor-dependent variations. Any RTU that claims to support DNP3 protocol must adhere strictly to this rule. However, the more capable and advanced RTUs have managed to include additional features that do not relate to the actual protocol features/properties or the manner in which DNP3 data in a message is transferred. These additional features focus on the communications itself, which is, getting data from one location to another, effectively and efficiently. • Peer-to-peer communications: This allows for local communications between two DNP3 devices. If communications to a top-end DNP3 SCADA master is lost, then local RTU systems (like a booster pump station and tank) can continue to operate with all data logged. • DNP3 message pass-through: The DNP3 protocol is primarily a pointto-point protocol. Point-to-point type communication architecture is not always feasible in a water and wastewater telemetry system. As such, the more advanced RTUs have the ability to receive a DNP3 message on one port and resend via a second port, allowing for more advanced communication options.

• Data concentration: In a multilayered telemetry system, there are inevitably going to be sub-master RTUs. DNP3 does not have the ability to request local and outstation data from a single RTU. As such, a submaster RTU would have the ability to map data received from an outstation DNP3 device to a new DNP3 object (address), while maintaining all of the original values and properties as provided by the outstation RTU.

Conclusion DNP3 is a modern, robust, intelligent and truly open protocol. While it has been around for close to two decades now, and thus a truly tried and tested protocol, it is still an evolving protocol. This is illustrated by the addition of secure authentication. A water and wastewater telemetry system is a complex system with a number of assets and locations to monitor and control. From a communications perspective, it can be a multilayered system using a variety of communications media such as radio, cellular, PSTN and fibre to interconnect sites. The DNP3 protocol, with its many features, helps enormously in implementing such a complex system and it does help in reducing the complexity of a system. This in turn will help reduce operational and maintenance costs for the end user. CSE-Semaphore Pty Ltd Contact info and more items like this at wf.net.au/M897

APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

POE-POWERED PANEL PC The Afolux AFL-057A is a 5.7″ Power over Ethernet (PoE) all-in-one panel PC that integrates the low-power Intel Atom Z510/Z530 processor (up to 1.6 GHz), an LCD touch panel and PoE function into a compact, fanless form factor. The 5.7″ LCD panel is an LED backlit resistive touch screen that is 4-wire resistive touch capable. The panel PC also features a compact flash slot, IP64 front panel protection from dust and spills, low power consumption and a wide operating temperature of -20 to 60°C. The AFL-057A is IEEE 802.3af compliant which eliminates the need for AC outlets. The IEEE 802.3af PoE standard ensures that 12.95 W of DC power is supplied to each connected device. PoE technology allows the system to safely transfer power and data to remote devices via the one cable (standard category 5e) within an ethernet network. The high graphic performance of the Intel Z510P/Z530P 1.6 GHz processor supports full hardware decoding for H.264, MPEG2, VC1 and WMV9. This eliminates the need for software decoding, therefore avoiding the risk of overloading the processor. Multitasking is optimised with low CPU resource utilisation. ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/P195

SAFETY LIGHT CURTAIN WITH INTEGRAL MUTING The Banner Engineering EZ-Screen low-profile safety light curtain with integral muting is designed for use on smaller production machines. The two-piece optoelectronic safeguarding device creates a screen of synchronised, modulated infrared sensing beams that extend from end-to-end of the housing - ensuring operators are completely protected from machine safety hazards. They are highly immune to EMI, RFI, ambient light, weld flash and strobe lights, and come equipped with factory burned-in emitter and receiver circuitry for toughness, dependability and vibration tolerance. The EZ-Screen LP with integral muting has a sensing range that spans from 100 mm to 7 m. Offering seven different, predefined muting configuration options - including bypass, mute-dependent override, mute enable and mute-cycle time extensions for L-style cell exit application - the safety light curtain suits diverse application requirements. Capable of two or four mute device/sensor hookup options, including a cost-effective, twosensor, X-pattern solution used for material entry and exit applications and an L sensor solution that minimises the floor space in manufacturing cell exit applications, the EZ-Screen LP with integral muting provides enhanced application flexibility. The optional CSM muting splitter cordset provides a complete QD connectorised solution for a simple, low-cost installation. Featuring a built-in muting function, the EZ-Screen safety light curtains do not require a third box, which helps facilitate easy set-up, minimises wiring requirements and reduces installation costs. Set-up can be performed without a PC, handheld programmer or other device; and DIP switch configuration features many of the same functions as a standard EZ-Screen LP. Micromax Pty Ltd Contact info and more items like this at wf.net.au/P309

8 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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IR-Fusion Made Easy.

Full infrared: Displays a full screen infrared view for maximum infrared detail.

Patented Fluke technology

AutoBlend ™ identifies problem areas faster

Multiple viewing modes

Picture-in-picture: Maintains a frame of reference by placing an IR “window” within a digital image.

More than picture-inpicture

Don’t be fooled by imitators

AutoBlend™ mode: Only Fluke has mastered the ability to blend partiallytransparent infrared and digital images for easier problem detection.

Infrared images alone can be difficult to understand, which is why Fluke pioneered IR-Fusion technology. ®

Fluke IR-Fusion technology is the industry’s only pixel by pixel alignment of digital and infrared images, providing the highest level of clarity and accuracy in the industry. Others have tried to copy, but no one has matched this powerful feature. Turn to Fluke patented IR-Fusion technology to deliver the industry’s best infrared images.

Find out more at www.fluke.com.au Fluke thermal imagers with IR-Fusion technology may have different on-camera viewing capabilities— all views are available in SmartView software. ®

NEW PRODUCTS

MULTIPARAMETER TRANSMITTER AND DISPLAY The Signet 9900 SmartPro transmitter from GF Piping Systems features multiparameter capabilities, flexible modularity and an auto-sensing backlit display with ‘at-a-glance’ visibility, even in dark conditions. It provides a single channel interface for many different parameters including flow, pH/ORP, conductivity/resistivity, pressure, temperature, level, salinity and other sensor types that output a 4-20 mA signal. The large (9.9 x 9.9 cm) auto-sensing backlit display allows visibility at a greater distance and large characters reduce the risk of misreading or misinterpreting the displayed values. The display shows separate lines for units, main and secondary measurements as well as a dial-type digital bar graph. Plug-in modules enable the unit to be adapted to meet changing needs.

MULTIFUNCTION FIELD CALIBRATOR

Optional modules

The Beamex MC6 Advanced Field Calibrator and Communicator is one

include relay, direct

device with five different operational modes, which means that it is

conductivity/resistivity,

fast and easy to use, and users don’t have to carry multiple pieces of

H Comm and a PC

equipment in the field. The operation modes include meter, calibrator,

Comm configuration

documenting calibrator, data logger and fieldbus communicator. In ad-

tool. The unit can

dition, the MC6 communicates with Beamex CMX Calibration Software,

be used with default

enabling fully automated and paperless calibration and documentation.

values for quick and

Developed from several years of market research and customer feedback,

easy programming or

the MC6 is an advanced, high-accuracy field calibrator and communicator that offers calibration capabilities for pressure, temperature and various electrical signals. It also contains a full fieldbus communicator for HART, FOUNDATION Fieldbus and Profibus PA instruments. Ease of use has been improved with a 5.7″ colour touch screen and mul-

can be customised with labelling, adjustable minimum and maximum bar graph settings, and unit and decimal measurement choices. The device also allows third-party 4-20 mA signals to be used as an input with an 8058 converter.

tilingual user interface. The robust IP65-rated dust- and water-proof casing,

The 9900 is offered in both panel- or field-mount versions.

ergonomic design and light weight make it a suitable measurement device for

Both configurations can run on 12-32 VDC power (24 VDC

field use in various industries, such as pharmaceutical, energy, oil and gas, food

nominal). The 9900 can also be loop powered with compat-

and beverage, service as well as the petrochemical and chemical industries.

ible sensors. Output accuracy is ±32 µA maximum error

Beamex is also introducing a new version of the CMX Calibration Software

at 25°C and 24 VDC with a resolution of 6 µA or better.

that, together with the MC6, offers improved possibilities for paperless calibra-

Standards and approvals include NEMA 4X/IP65, CE, UL

tion management.

and China RoHS.

AMS Instrumentation & Calibration Pty Ltd

Georg Fischer Pty Ltd

Contact info and more items like this at wf.net.au/M960

Contact info and more items like this at wf.net.au/M493

10 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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NEW PRODUCTS

pH TRANSMITTERS Rosemount Analytical 1066 transmitters are suitable for many industrial applications including those with exacting performance requirements such as pharmaceutical and food and beverage and in harsh environments such as chemical plants, metals processing and effluent monitoring. The 1066 series supports HART 7 and is registered under the Interoperability Test Kit 6 (ITK6) for FOUNDATION Fieldbus. The Rosemount Analytical 1066 family of transmitters can measure pH, ORP, resistivity/conductivity, percent concentration, total dissolved solids, total chlorine, free chlorine, monochloramine, dissolved oxygen and dissolved ozone. A second sensor input allows continuous pH correction for free chlorine measurement. The instruments’ SMART capabilities also enable them to accept pre-calibrated Rosemount Analytical SMART pH sensors, saving time and money for field technicians. The 1066 Foundation Fieldbus transmitter can use analog output function blocks to link to temperature and pressure measurements from the bus for temperature and pressure compensation, which can increase the accuracy and responsiveness of the measurement. The 1066 also has a full complement of analog control and math function blocks, for use by the 1066 or other devices on the bus, to facilitate control in the field. The HART version of the 1066 is switchable between HART 5 and 7, allowing the 1066 to be used with HART 7 capable hosts, as well as legacy hosts. Housed in a 1/2 DIN enclosure, the 1066 series features a large display to provide ease of use and an intuitive menu system. The 1066 is also compatible with the Emerson Smart Wireless THUM adapter. Emerson Process Management Contact info and more items like this at wf.net.au/N224

Customise

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The Micro800™ Family of PLCs gives you the best of both worlds with standalone functionality and component capabilities. Together with the Connected Components Workbench™ Software, you get: • Just enough control • One software • Easy to install and maintain • Convenience and connectivity • Part of the Connected Components bundle

Plug-ins

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The Micro800™ Family of PLCs Outstanding solutions made outstandingly simple www.rockwellautomation.com.au

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12 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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NEW PRODUCTS

ETHERNET SWITCHES Hirschmann RSP ethernet switches offer redundancy with zero switchover time. They are designed for use in the field-level networks of power supply companies, but they also can be used in any situation where uninterrupted communication is required. These robust fanless switches have eleven ports, three of which can be used for SFP transceivers. They support Fast (100base-FX) or - optionally - Gigabit ethernet (100/1000base-FX). The remaining eight ports can be used either for 100base-TX or as a combination of four SFP transceivers and four TX ports. Additional features include comprehensive management, diagnostic and filter functions plus a variety of redundancy methods and expanded security mechanisms. In addition to the standard configuration, Hirschmann also offers a version that supports highly precise synchronisation compliant with IEEE 1588v2, plus PRP (Parallel Redundancy Protocol) and HSR (High-availability Seamless Redundancy). This means that it is possible to implement networks that guarantee uninterrupted data communications with the attached systems and can thus - in the case of the electricity supply industry - guarantee reliable power supplies to end customers at all times. These switches have high vibration resistance and extensive resilience

PROGRAMMABLE STEPPER DRIVES RTA has launched three models of stepper drives that incorporate motion controllers and range from 24 VDC to 240 VAC supply. In many cases, this eliminates the need for a separate motion controller, reducing the cost and size of the system. An added advantage is that the programming language used is specially designed for motion control rather than the standard PLC-based languages. Several motion programs can be loaded into the drive and stored. A program is selected using dedicated inputs in BCD and run using a Start input. The drives run standalone so it is not necessary to have a computer or PLC connected at all times. The drives also have several digital I/Os, a datum switch input and emergency stop input. For multiaxis machines, up to 48 drives can be linked on a single serial line. Several instructions are available such as indexed run with or without ramp, free run with or without ramp, run with programmable braking distance, time delays, conditional jump, For/Next loop and programming in absolute or relative coordinates. Some drives have an optional analog speed control via an external potentiometer

to magnetic fields and electrostatic discharges. Redundancy methods

or an analog DC voltage.

such as PRP, HSR and PRP/HSR Redundancy Box, RSTP, MRP and

Automated Motion Systems Pty Ltd

Fast MRP ensure a high level of network availability.

Contact info and more items like this at wf.net.au/M920

Mounted on DIN rails, the switches can easily be activated by plugand-play and feature sturdy, compact stainless steel housings measuring 100W x 164H x 116D mm. Belden Australia Pty Ltd Contact info and more items like this at wf.net.au/M491

APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

PRESSURE SWITCH The PSD-31 pressure switch has a flush

Motrona’s encoder signal expanders are rail-mounted modules designed to take

the pressure channel and prevent possible contamination of the process. WIKA Australia

WF.NET.AU/N115

ENCODER SIGNAL EXPANDERS

diaphragm to help eliminate clogging of

the signals from one incremental square wave output encoder and expand it to two or more encoders. Plant Control & Automation

WF.NET.AU/N270

INFRARED THERMOMETERS The Ircon Modline 7 Series infrared thermometer is a rugged, IP65 sealed sensor system for continuous temperature monitoring up

to 3000°C. AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/N095

LEVEL DETECTOR FOR SOLIDS The FTI77 is a compact capacitive point level transmitter that can be

used for point level detection at high be operated in minimum or maximum failsafe mode.

temperatures in bulk solids and can

Endress+Hauser Australia Pty Ltd

STAINLESS STEEL PANEL PC

WF.NET.AU/N268

The IPPC-8151S is a fanless industrial panel PC with a 15″ XGA TFT LCD, an Intel Celeron-M 1 GHz CPU, and a chemical-resistant touchscreen. Advantech Australia Pty Ltd

WF.NET.AU/N333

14 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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NEW PRODUCTS

THREE-PHASE POWER QUALITY ANALYSERS The Fluke 430 Series II three-phase power quality analysers are designed to help facilities reduce electrical power consumption and improve the performance and lifespan of electromechanical equipment by providing the return on investment (ROI) justification to mitigate power quality distortion. With the Unified Power function of the 430 Series II, electricians, utility technicians, electrical engineers, field service technicians and energy consultants can now have the ability to automatically quantify the energy wasted by harmonics and unbalance; and by inputting the utility rate structure, the user can even calculate the monetary cost of the wasted energy. While these new models consume less energy as individual installations, they increase the level of power quality disturbance in the overall electrical system, increasing waste energy due to harmonics and reducing the total potential energy savings. The Fluke 430 Series II calculates the monetary cost of that waste energy. The Series II models have up to 32 GB (8 GB standard) memory, a swappable SD memory card and USB connectivity for longer power, energy logging and faster data download. Screen quality and battery life are both improved and the accompanying software has been redesigned to give users more options to analyse both power quality and power consumption. Both models are fully compliant with the IEC 61000-4-30 Class-A standard. Each one can monitor systems with up to 10 power quality parameters on one screen and can record up to 150 parameters on four phases simultaneously, in accordance with the EN50160 standard, and are safety rated 600 V CAT IV/1000 V CAT III. Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/M803

INCLINOMETERS Fraba Posital has introduced industrial and heavy-duty versions of its Accelens (ACS) inclinometers, featuring either a plastic or aluminium housing. In many applications, these non-contact sensors can be used as an alternative to rotary encoders. The units feature capacitive sensor cells based on MEMS technology (microelectromechanical systems) and allow users to measure inclination values directly, requiring no mechanical coupling to drive elements. Mounting fixtures and couplings are therefore rendered unnecessary, minimising the constructive effort compared with other solutions. The inclinometers are available as single-axis models with a 360° measuring range and as double-axis models with a ±80° measuring range. They provide a 0.01° resolution at a 0.1° measuring accuracy. A high sampling rate of up to 100 measurements/s enables an efficient filtering of vibrations and shocks and minimises the settling time. Depending on the model, the robust devices provide IP68 or IP69K protection. They are available with SSI, CANopen, DeviceNet or fieldbus interfaces and with analog voltage or current outputs. Designed for a wide temperature range (-40 to +85°C), they can be used under extreme environmental conditions, such as in mobile machinery. Plant Control & Automation Contact info and more items like this at wf.net.au/M805

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CLEVER PUMPING Sanna-Kaisa Ehanto, ABB Drives, Helsinki, Finland

Climate change, increasing water demands due to global urbanisation and regulatory obligations are all making the water sector an attractive arena for technologies that can help reduce costs and contribute to reducing the effects of climate change. It is against this backdrop that the demand for intelligent process control equipment is surging throughout the water industry.

ariable speed drive (VSD) manufacturers are in the vanguard of the development of intelligent devices. The functionality being demanded from VSDs is manifold and includes enhanced connectivity, reduced energy consumption, minimised downtime and features that intelligently react to, as well as prevent, real problems, preferably before they cause damage. The growing use of VSDs, particularly intelligent drives for pump control, represents a major departure from the standard operating practice of using control valves to vary fluid flow. With its low energy usage and low maintenance outlay, the total life cycle cost of a VSD-controlled pumping system can be significantly less than traditional pump technology. Other VSD benefits include smoother start-ups and production changes, more precise control during continuous operation and faster diagnosis of potential system problems before product quality or process operation is negatively affected. The emergence of intelligent pumps is a critical step forward in the evolution of process management. With embedded intelligence, VSDs can provide pump control, pump condition monitoring, protection and traditional energy-saving benefits. Figure 1 shows a summary of the benefits of VSDs at the various operating points of a motor.

Pump cleaning Consider, for instance, the antijam or antiragging function now found in several VSDs. A long-standing problem suffered by water companies is that of â&#x20AC;&#x2DC;raggingâ&#x20AC;&#x2122;, the fouling of pump impel-

18 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

lers which consumes thousands of hours of maintenance time in sewage pumping stations and wastewater treatment plants around the world. Manually clearing the problem is a costly and unpleasant task requiring a maintenance team and frequently a crane. Downtime may extend to several days, during which time the backup systems are under additional pressure. A total system failure can result in effluent leakage, which has environment and human health implications as well as clean-up costs and legislation issues. The antijam function prevents pumps and pipes from clogging by initiating a sequence of forward and reverse runs of the pump to clean the impeller.

Dedicated drives for pumps But it is not just by unclogging impellers that the latest intelligent drive technology can enhance a pumpâ&#x20AC;&#x2122;s life cycle. In fact, there are several pump-specific requirements that can be bundled into the functionality of the drive module that can make a drive specific for water and wastewater applications. The idea of application-specific drives is something which IMS Research, a leading supplier of market research, has identified as a growing trend. With such drives, the user can reduce their total cost through shorter start-up times, lower integration costs and improved machine productivity. IMS Research estimates that low-voltage AC drive shipments to the global water and wastewater market will grow from US$448 million in 2010 to US$760 million in 2014.

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Motors & drives

units at night. This allows for better maintenance planning and can boost energy efficiency by operating pumps closer to their best-efficiency point.

Energy saving

Pumps are by far the biggest application area for variable speed drives. And all these pumps have specific requirements from flow calculation through to level control, all of which can be solved using the latest software now available. The drivesâ&#x20AC;&#x2122; pumpspecific functions decrease the life cycle cost of the pumping systems, helping to save time and money, boost energy efficiency and reduce carbon dioxide emissions. Typical of the applications which can now benefit from intelligent pump control are water pumping stations, many of which demand, in addition to the antijam feature mentioned above, level control and pump priority functions.

Level control Level control is designed to control the filling or emptying of storage tanks containing wastewater or stormwater contaminated with dirt, gravel, litter and other debris. The function seeks to prevent sediment build-up on the tank walls by randomly varying the surface level within a preset range. Additionally, aggressive, fast-ramp starting creates a flush effect, thereby preventing blockages, while minimising energy consumption by running pumps within a favourable operating area.

Pump priority Pump priority schedules pump operation to enable maintenance planning. It is intended for systems where the consumption rate varies with demand. For example, the drive can be programmed to operate higher capacity pumps during the daytime and smaller

Energy saving lies at the heart of VSD use in pumping systems. In general, the life cycle costs of a pump system depend on the power range and its in-service lifetime. However, typical costs for pump systems between 50 to 100 kW will be incurred through energy usage (between 70-80%) and maintenance (20-30%). Over a 20-year period, the combined energy and maintenance costs may exceed 10 times the initial pump purchase price. These operating costs can be dramatically reduced through efficiency improvements. Two common causes of pump system efficiency loss are pump oversizing and throttled valves. Poor pump performance can result in downtime, collateral damage to equipment and high maintenance costs. In VSD-controlled pumping systems it is also possible to run the pump at higher than nominal rotational speeds. Normally, the motor is designed so that it enables operation in the area of higher power range. This makes it possible to run the same VSD-controlled pump in a higher power range area compared to an on-off controlled pump. This mode of operation enables a pump with a smaller power rating to be used, which also reduces initial investment cost. This is valid for situations in which peak flows occur every now and then (see Figure 2). The energy-saving benefits of VSDs are well documented, with savings typically from 20 to 60% readily achievable in speed-controlled pump applications. Now, as part of the added intelligence within a drive, manufacturers are including features such as energy optimisation, which improves the total energy efficiency of the pumping system. Tracking this entire energy saving is possible through in-built energy counters that show how much energy has been used and saved in kWh, currency or volume of CO2 emissions.

Pressure and flow control Using VSDs to control pressure and flow improves flow management, minimises maintenance and reduces electrical energy requirements. A pressure boosting station, for example, feeds water directly into the distribution system and seeks to maintain a constant pressure in the pipes. With smooth VSD control there are no pressure shocks causing noise, erosion or leakage in the pipeline. Intelligent VSDs also increase uptime: parallel drives enable the system to run with 100% redundancy. If a defect occurs in one of the pumps, motors or drives, the others will continue operation without any interruption. Pump stations are sometimes located remotely

APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 19

Motors & drives

Figure 1: Summary of a VSD’s benefits at various motor operating points.

Figure 2: Power consumption for various control methods.

and service activities might take some time. With redundancy, the pump station operation is trouble free with minimised downtime. Further, the running time of the pumps can be controlled with the pump priority function (see earlier) to ensure that wear and tear on all pumps is the same. Where several parallel pumps are operated together and the required flow rate is variable, a function called multipump control maintains stable process conditions optimising the speed and number of the pumps needed. This function provides the most energy-efficient way to operate parallel pumps.

pumped volume to be monitored by the VSD, without any additional components. This is a useful feature in systems where data about the total flow during a specific time period is needed.

Sleep and boost Another pressure-related function is that of sleep and boost. Traditionally, standard PID control may allow a pump to operate at undesirably low speeds for prolonged periods of time. This can cause mechanical issues with certain pump types and in general wastes energy, since most pumps do not generate significant flow at low speeds. A sleep and boost function, however, lets the drive go to ‘sleep’, meaning that the drive output will shut off and the pump will stop. This is suitable for clean water pumping systems during night-time when water consumption falls. If the system pressure drops below a defined level, this function detects slow rotation and runs the pump to boost the pressure in the pipeline or water level in the tank prior to shutdown. This extends the pump’s sleep time and therefore saves energy. The pressure is continuously monitored and pumping restarts when the pressure falls below the minimum level. It also avoids unnecessary starting and stopping and helps to flush the pipelines.

Flow calculation Another feature now built into drives is flow calculation. This function provides the drive with a flow meter routine that enables the

20 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

Remote monitoring Some drives can connect to major automation systems via an ethernet connection or GSM wireless network. This is achieved with a dedicated gateway concept between the fieldbus systems and the drives. A remote monitoring module gives simple access to the drive via the internet, communicating via a standard web browser. The user can set up a virtual monitoring room wherever there is a PC with an internet connection or via a simple dial-up modem connection. This enables remote monitoring, configuration, diagnostics and, when needed, control. Remote monitoring provides easy access to pumping systems, even in faraway locations, thereby avoiding unnecessary site visits and saving time. Through the use of ethernet adapters, process data, logs and event messages concerning pumped volumes, tank levels and other operating conditions can be sent independently.

Summary Drive modules specially designed for water and wastewater applications can significantly enhance a pump’s life cycle. With up to 60% energy savings possible along with reduced carbon dioxide emissions and payback on investment often within two years, the future for the intelligent variable speed drive is certainly looking bright.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/N103

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NEW PRODUCTS

pH SENSOR The Rosemount Analytical Model RB pH sensor is designed for optimum sensor life in demanding scrubber applications. pH sensors are most vulnerable to failure due to poisoning of the reference junction. The RB sensor features a proprietary multijunction that hinders reference poisoning. This design is particularly successful against aggressive sulfides found in scrubbers. The unique multijunction reference chamber of the RB extends survivability. In addition, the sensor is built of chemically resistant Kynar, adding to its long life. Instead of replacing the entire sensor, the Model RB sensor can be reassembled inside its titanium sheath, high-pressure body, reducing costs for replacement and shipping. The sensor allows for optional installation methods including inline, submerged or ball-valve insertion. Emerson Process Management Contact info and more items like this at wf.net.au/N223

COMPACT SWITCHES

HIGH-TEMPERATURE PRESSURE TRANSMITTER The Series 35X HTC high-temperature pressure transmitter from Keller is primarily designed for biotechnology and food industry applications. The pressure of hot media applied to the diaphragm is transferred via an exposed oil-filled spiral capillary to the sensing element. Heat to a maximum of 300°C is therefore safely dissipated to the atmosphere before it reaches the sensing element when the sensor is optimally mounted. The 35X HTC is based on the existing Series 30 digitally compensated pressure transmitter range. The 35X HTC is available in ranges from -1 to 3 to 0 to 1000 bar. While the linearity (BSl) is 0.05%FS, the combined error is 0.5%FS for the entire operating temperature band from 20 to 300°C. The frequency response is 100 Hz. Both analog and digital output signals are standard, including RS485, 0-10 V and 4-20 mA. It is possible to use both digital and analog signals concurrently. Supply voltage is 8-28 VDC for the RS485 and 4-20 mA outputs. The 0-10 V signal requires 12-30 VDC input.

The managed switches from Phoenix Contact’s Factory Line range have been

Several choices of interface cables are available within

expanded to include several types of switches that are preset for EtherNet/IP.

the Keller product range to communicate between the

These compact switches feature IGMP snooping and multicast detection func-

35X HTC and a PC. PROG30 PC-compatible software is

tions that are activated upon shipment, enabling the switches to be integrated

available to set up and calibrate the Series 35X HTC, to

with minimal configuration into EtherNet/IP applications.

rescale it from 100% down to 30% FS, to adjust the zero,

With the version 3.40 firmware, the switches have the Auto Query Port expan-

change the measurement unit and enable several other

sion, which allows fast forwarding of EtherNet/IP telegrams after a redundancy

functions. READ30 data acquisition software is also available

toggle. The switch configuration can also now be saved on an external PC.

to facilitate various graphical presentations, as well as to

The version 3.40 firmware is available immediately for download.

monitor up to 16 transmitters on the one serial connection.

Phoenix Contact Pty Ltd

Bestech Australia Pty Ltd

Contact info and more items like this at wf.net.au/M934

Contact info and more items like this at wf.net.au/P164

Check out this magazine’s sister website. 22 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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Order Today, Ships Today! More than just a great online store In addition to our main Web site, www.automationdirect.com.au, we have a whole network of support sites to help you quickly and efficiently choose and use the automation products you need. In addition to our DVD catalog, we have an online network of information available 24/7. FREE videos, FREE software, FREE documentation, FREE support, FREE magazine . . . . . . well you get the point. :-)

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NEW PRODUCTS

IN-PROCESS SPECTROPHOTOMETERS Carl Zeiss offers a wide range

DUAL BULK BAG FILLING SYSTEM

of spectrophotometer modules

The Dual Bulk Bag Filling System from Flexicon integrates two Swing-Down bulk bag fillers with a

for sensitive multichannel inline,

Flexicon Pallet Dispenser and powered roller conveyors, allowing safe, high-capacity filling of bulk bags

online and at-line measurements.

of all popular sizes. Programmable controls allow the fillers to operate separately or simultaneously, filling bags of the same size or two different sizes.

The MMS family of miniature spectrometer modules with CCD

When a filling cycle is initi-

detectors enable simultaneous

ated by push-button or contact

high-precision colour measure-

closure, pallet dispenser forks

ments in up to four wavelengths

lower the stack of pallets onto

on a single system for the spectral

the roller conveyor, withdraw

range between 350 and 950 nm.

from the bottom pallet and

Compact MMS modules can

raise the remaining pallets,

be used to accurately conduct

allowing the roller conveyor

content analyses, monitor layer

equipped with photoelectric

thickness or mixture homogeneity,

sensors to move the dis-

inspect extrusion processes and

pensed pallet into position

perform colour measurements at

below the filling station.

any point in the manufacturing

The bag connection frame

process.

of the Swing-Down fill head

The family of MMS CCD mod-

allows an operator at floor

ules feature high sensitivity and

level to safely and quickly at-

can be configured for a wide range

tach bag straps to automated

of industries including plastics,

latches, slide the bag spout over an inflatable spout seal and press a spout seal inflation button.

chemical and pharmaceutical

The system then automatically pivots the bag connection frame back to horizontal, raises the entire

manufacturing, agriculture or food.

fill head, inflates the bag to remove creases, fills the bag at a high rate, finishes filling accurately at

With the family of MMS CCD

trickle-feed rate, deflates the spout seal, releases the bag loops, raises the fill head to disengage the

modules, the company also now

spout, rolls the bag out of the filling area, and rolls a new pallet into place to begin another cycle.

offers OEM spectrometer modules

The system is offered with the company's own mechanical or pneumatic material delivery system integrated with the user's upstream process equipment or other material source. Flexicon Corporation (Australia) Pty Limited

with integrated electronics unit. Carl Zeiss Pty Ltd

Contact info and more items like this at wf.net.au/P229

Contact info and more items like this at wf.net.au/M827

24 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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NEW PRODUCTS

FIELD-INSTALLABLE RJ45 PLUG Harting has released a range of highspeed 8-pole RJ45 connectors. The RJ Industrial 10G is an upgrade of Hartingâ&#x20AC;&#x2122;s RJ45 connector that requires no tools for connection and features a future-proof design for 10 gigabit ethernet. The connection is made reliably and quickly using insulation displacement terminal technology. The insulation displacement terminals are designed for rigid and flexible conductors with a broad range of wire cross-sections. Cables with diameters from 4.5 to 9 mm are securely fixed in place in the connector with a newly developed cable gland. This allows users to connect all customary ethernet cable types with this one RJ45 connector type. Due to a compact design, the rugged IP 20 model is also suitable for multiport RJ45 jacks. In addition to the IP20 models, all known IP65/67 PushPull types up to Han 3A are now available with this insert. Soanar Limited Contact info and more items like this at wf.net.au/M924

PRESSURE GAUGE WIKA has expanded its offer of digital pressure gauges with the model CPG500 that offers a high degree of measuring accuracy and speed. A digital pressure gauge combines the accuracy of digital technology with the simplicity of an analog pressure measuring instrument. Given its very high sampling rate of 100 measurements/s, the CPG500 is suitable for capturing fast pressure peaks and drops. It also operates with a high accuracy of 0.25% of span, and can be used both for pure pressure measurement and for the calibration of most analog pressure gauges. With its robust case and its simple, four-button operation, the CPG500 is a cost-effective alternative to the model CPG1000 precision digital pressure gauge. WIKA Australia Contact info and more items like this at wf.net.au/N114

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APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

NEW PRODUCTS

All the Tools You Need for Embedded Measurements and Control, in one rugged box.

RS485 INPUT SAFETY BARRIER The Mornsun TD100-EX-485 is a DIN rail-mounting, RS485 half-duplex digital output safety barrier. The detection side isolated safety barrier can supply isolated DC power from the transmitters in the security zone to the danger zone, transform the RS485 digital signal of the danger zone into isolated RS485 or RS232 with digital signal transmission to the security zone while increasing the anti-jamming capability of the industrial production process control system, to ensure system stability and reliability. Only one independent power supply is required, 18-32 VDC. The series has 3-port isolation (input, output and power supply) with a high isolation voltage of 2500 VAC and MTBF claimed to be greater than 500,000 hours. Three coloured LEDs indicate status for power on, transmitting and receiving. These devices meet IEC/EN61326 standards with safety class IP20 (IEC60529/EN60529). DLPC Pty Ltd Contact info and more items like this at wf.net.au/N232

UPGRADED PROCESS AUTOMATION SYSTEM Rockwell Automation has extended the reach of its PlantPAx process automation system to integrate critical rotating assets such as compressors, pumps, turbines and fans, giving users the ability to manage plant-wide operations with a single platform. The system combines the company's core process automation capabilities and technologies ■

Graphical Software

■

Sensor Connectivity

■

Signal Analysis

■

Control Algorithms

■

Custom Timing

■

Custom Triggering

■

Actuator Connectivity

■

Embedded Storage

■

Industrial Networks

■

Expansion Systems

The NI CompactRIO hardware platform can handle your embedded measurement and control applications, and do it in a way that outperforms other off-the-shelf systems so you don’t have to spend time developing a custom solution. The range of high-quality measurements, coupled with an extremely rugged design and the ability to modify the hardware using NI LabVIEW system design software, gives you all the benefits of customization with the convenience of an off-the-shelf platform.

with those of partners and acquisitions to deliver an integrated control and information solution. Users can now tie intelligent motor devices into this unified-control architecture, making an immediate and measurable impact on asset availability, operational efficiency and energy management. The tight integration between process automation and motor control is especially beneficial in heavy industrial applications with considerable mechanical investments, such as metals, mining, cement, power, oil and gas, water/wastewater, and pulp and paper applications. Users will have access to diagnostic information on any device in the system from any location - including motor control centres, drives, compressors, pumps, fans and instrumentation. Leveraging the EtherNet/IP network, engineers can monitor process conditions such as electric motor current, vibration signatures of key rotating assets and torque signatures of variable speed drives. This allows plant engineers to predict potential problems and help avoid equipment downtime -

>> To learn more about CompactRIO, visit ni.com/compactRIO

resulting in improved productivity and reduced maintenance costs.

1800 300 800

Other key features with the system include EtherNet/IP network support for redundant systems and device-level ring network topology that provides a highly available EtherNet/IP network without any additional infrastructure costs; improved device integration and asset

©2012 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 05309

26 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

management; and accelerated design engineering. Rockwell Automation Australia Contact info and more items like this at wf.net.au/P172

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NEW PRODUCTS

ACTIVE HARMONIC FILTERS AcF series active filters from Maschinenfabrik Reinhausen (MR) are suitable for threephase, 3-wire and three-phase, 4-wire systems and are available both in 415 and 690 V versions. The AcF series active filter uses a special T-sine reconstruction filter between the network and the IGBTs in each module in order to provide a significantly lower switching frequency, thereby minimising losses and maximising the lifetime of IGBTs. They are available in current ranges from 100 to 600 A and up to 4800 A in parallel. They have a low power loss of 1900 W per 100 A module, and offer both global and selective harmonic compensation to the 50th harmonic and a response time of 1 ms compared to, typically, 20 ms for other active filters. The AcF series active filter has a unitised and modular construction, and an embedded web server means that no special software is necessary. Both open-loop and closed-loop configuration is possible. The closed-loop configuration is used to comply with the THID injected into the grid. The open-loop control is used to provide compensation for an individual or a group of nonlinear loads inside the plant facility. The active filters can also be used for MV compensation via an interposing transformer. In this capacity the filters are employed in three-phase, 3-wire sub-distribution networks. Westek Electronics Pty Ltd Contact info and more items like this at wf.net.au/M708

Wireless and battery-less pushbuttons Significantly reduce your installation time and achieve cost savings of at least 20 per cent

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Harmony Ø22mm XB4 Metal and XB5 Plastic Pushbuttons

Harmony Ø22mm Fingerprint Recognition Biometric Switch

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APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

NEW PRODUCTS

OPTIC FIBRE TESTER The Fluke OptiFiber Pro OTDR is an optical time-domain reflectometer (OTDR) with a smartphone interface. The smartphone interface supports gesture-based commands and technology enhancements that simplify testing in data centre environments, minimising the learning curve typically associated with older OTDRs by greatly reducing complexity. A simplified â&#x20AC;&#x2DC;datacentre modeâ&#x20AC;&#x2122; automates the process of setting test parameters, like wavelength or end-detection algorithms, significantly reducing the set-up time and the complexity of learning how to troubleshoot data centre problems. With a short event and attenuation dead zones, it is capable of testing connectors and patch cords as short as 0.5 m. This is critical in virtualised server environments, where connections are often less than 1 m and hidden performance issues can severely decrease the reliability of data centres. Through visual fault presentation the OptiFiber Pro shows all fibre events graphically letting any user quickly and easily interpret OTDR trace results, and built-in project management tools facilitate the assignment and tracking of fibre testing projects for multiple users, increasing efficiency, enhancing project tracking visibility and enabling cost-effective device sharing. Upgraded LinkWare management software helps simplify workflow management, integrates test results and keeps the OTDR up to date with the latest software. Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/N189

28 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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NEW PRODUCTS

PRESSURE SWITCH WITH FLUSH DIAPHRAGM THERMAL IMAGING CAMERA An addition to FLIR Systems’

For industrial processes with critical media, WIKA has expanded its range of electronic pressure switches with the PSD-31 with flush diaphragm. The instrument is suitable for application in abrasive, aggressive, adhesive,

E-Series range, the FLIR E30

crystalline and viscous media. Its flush connection eliminates any clogging of

thermal imaging camera is suit-

the pressure channel with particles and also prevents possible contamination

able for electrical and mechanical

of the process.

maintenance inspections.

Technically, the new pressure switch is the same as the PSD-30. Due to its

The E30 has a 2 MP visual

small size and the ability to rotate both the display and connection, it offers

camera that enables the operator

mounting flexibility. Its simple menu structure (in accordance with the VDMA

to reference the position of the

standard) enables quick and easy operation, while a large LED display provides

identified problem with a visual

high readability. The switch is available in several country-specific versions, for use

image. The thermal and visual

worldwide. Its quality and safety are documented by its cULus listing.

images are stored simultaneously

WIKA Australia

by pressing a button.

Contact info and more items like this at wf.net.au/N115

For darker environments, an LED lamp at the front of the camera may help ensure goodquality images are captured. As with all the E-Series range, the E30 has a laser pointer to help the user associate the hot spot on the thermal image with the real physical target in the field. An uncooled vanadium oxide microbolometer detector produces clear thermal images of 160 x 120 pixels, allowing temperature differences as low as 0.1°C to become visible. The camera measures temperatures from -20 to +350°C. The rugged outer casing protects the inner core and is IP54 rated. The 3.4" LCD touch screen shows thermal images and allows users to access all camera features. Cameras from the FLIR E-Series come with FLIR Tools software, which imports thermal images from the camera to a PC and allows users to control layout, move images and resize measurement tools. It creates PDF imagesheets of specific images; adds headers, footers and logos to reports; and applies filters when searching for images. Users that require more reporting functionalities can select FLIR Reporter software, which is also compatible with the E-Series cameras. FLIR Systems Australia Pty Ltd Contact info and more items like this at wf.net.au/N172

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APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

Making Air Technology

zone sponsor

zone partner

media partner

Reliable pallet labelling for CUB Carlton & United Breweries (CUB), Australia’s largest brewer, operates five breweries in Australia as well as breweries in Fiji and Samoa. Its Yatala Brewery in Queensland is one of the most state-of-the-art breweries in the world, producing 450 million litres of beer each year. With Yatala’s advanced brewing and packaging technology, there is no room for inaccurate, incomplete or illegible pallet labels that slow output and raise production costs. Australia’s major retailers require logistics labels with unique serial shipping container codes (SSCCs) to be applied to pallets delivered to their distribution centres so they can be scanned on receipt. To ensure the production line continued to meet industry standards for pallet labelling, CUB needed a time-saving and robust solution that could withstand a 24/7 production schedule. The solution also needed to apply labels at multiple heights while complying with trading partner requirements, including the GS1 barcoding standards for pallet labelling. Working closely with CUB personal, insignia, a strategic alliance partner of GS1 Australia, developed the Domino print-andapply label applicator system. The applicator sits within a sealed cabinet with a pneumatic door that opens only when a label is to be applied. The cabinet is designed to keep dust out, providing the Domino M-Series printer with an optimum operating environment. This ensures the printer and the print head are not degraded by dust and other materials commonly found in warehouse and production environments. A fully functional print head is vital for printing barcodes to GS1 standards. The pallet applicator at CUB comes with a standard check-scanner feature mounted to the tamp pad. This unit is protected via a sensor system to ensure it is not damaged during operation. The check scanner scans the barcode on the label to ensure that it is applied correctly and the barcode is readable. It then verifies that the correct label and related GTIN and SSCC are applied to the correct pallet and in the correct position.

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The Domino M-Series print engine operates with a 300 dpi print head. This high-resolution print head provides more options for the maximum magnification of the barcodes within the standards for the specific label size used. The scanner monitors the performance of the print head and the quality of the print head, and the media management of the print engine ensures a quality barcode is produced even when printing a barcode in ladder format. This has allowed insignia to deploy a 4″ 300 dpi print head at CUB and print the label in ladder format. Unique tamp-pad and tamp-arm cylinder technology within the system allows the label to be rotated 90° once on the tamp pad and applied in the correct orientation to the pallet. This means that if a pixel in the print head blows and a line is created in the print, it will not lead to an unreadable barcode as it will cut across the barcode bars leaving a legible barcode. A key feature of the pallet-labelling system developed for CUB is its automatic height adjustment capability. CUB has a core need to meet an industry requirement of applying a GS1 logistics label to unwrapped pallets. In this case they need to apply the label to the side of one carton only on the pallet - in other words, not overlapping another carton. The Domino M-Series SSCC pallet-labelling system’s automatic height-adjustment technology means

that once a label is printed onto the tamp pad, the tamp arm will then drop to the required height for the specific pallet configuration for the product on the pallet and apply the label to a single carton. As only the lightweight tamp arm is moving to meet these differing height requirements, there is less wear on the system and the arm can move quickly to apply the label in the shortest time possible. This feature can also be used to apply labels to part pallets within an operation. With this system in place the label is applied in the correct position according to GS1 standards so the pallet can be scanned on receipt at the retailers’ distribution centres. As a proactive business, CUB saw the potential supply chain benefits of implementing this system and the flow-on effects through this quality practice throughout their supply chain. Once a quality, readable GS1 logistics label is applied in the right location to the right pallet, products can be traced through the supply chain. To ensure consistent barcode quality, CUB Yatala has a comprehensive service contract with insignia that covers preventative maintenance and breakdowns. This means that their pallets continue to go out the door meeting GS1 standards. insignia Pty Ltd Contact info and more items like this at wf.net.au/N001

APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

NEW PRODUCTS

WIRELESS REMOTE NETWORK MODULE The WNM wireless network module from Moore Industries provides a low-cost wireless communications link between field sites that are in rugged or impassable terrain, with a single unit transmitting for up to 48 km and the ability to act as a repeater for a virtually unlimited transmission range, and in both point-to-point and point-to-multipoint network architectures. The bidirectional WNM employs spread spectrum frequency hopping technology to avoid interference problems caused by crowded radio spectra. This technology allows multiple radio networks to use the same band while in close proximity. Operating at standard operating frequencies of 902 to 928 MHz (48 km range) or 2.4 to 2.4835 GHz (24 km range), the WNM does not require a regulatory licence and can typically be installed without performing costly RF site surveys. When it is set in the Smart Switch Ethernet (SSE) mode, the WNM enhances the speed and reliability of data packet transmission by determining the most efficient path of broadcast (including direct to a single radio or to some or all radios in a network) on a packet-by-packet basis. The WNM can be used with the Moore Industries NCS NET Concentrator System, as well as other SCADA and distributed I/O systems. WNM models are available for data communications networks that use ethernet and serial (RS485) communications. The WNM utilises 128-bit AES encryption, 32-bit CRC error detection and ARQ for robust and secure communications. The industrial DIN rail-mount metal enclosure also ensures that the WNM can be used in rugged environments, including ambient temperatures from -40 to 75°C and relative humidity of 5 to 95%. Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/P246

How do you improve reliability and still save money? UE Solid State Pressure Switches

Improve reliability with UE electronic pressure and temperature Switches. Available for hazardous locations the One Series provides precise control and features Plugged Port detection. Solid State design with no moving parts Field programmable for set point and deadband control ■ 2-Wire design is a drop-in replacement for mechanical switches ■ IAW®(I am working) self diagnostics ■ Pressure ranges to 4500 psi/Temp. ranges to 1000°F ■ ■

Pryde Measurement Pty Ltd Ph: 1800 688 211 info@pryde.com.au Melbourne ❘ Sydney ❘ Brisbane ❘ Perth

32 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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NEW PRODUCTS

WEB-BASED OPERATOR PANELS The Phoenix Contact range of web-based operator panels now comes in 10 and 15″ versions. The larger display area has the advantage that fewer process diagrams have to be configured to display all operating data. For operator panels with small displays, information is distributed across various process diagrams. The navigation between the process diagrams defines how quickly and intuitively this operation can be performed. By using large displays, the risks involved in navigation are reduced, as users can see all of the information at a glance. The web panels with screen diagonals of 26.42 cm (10.5″) and 38.1 cm (15.1″) have a colour TFT touch screen. They have a resolution of 800 x 600 or 1024 x 768 pixels and can display 65k colours. Both devices are based on a RISC ARM9 platform, sporting a 200 MHz processor. These devices are factory equipped with one ethernet and two USB ports. These panels are used in equipment and small machines where basic HMI functionality is required. All web panels use the simple and free Web Visit development environment to visualise process flows, whereby a compact control is connected to the web panel as a web server for data processing and visualisation. Data is displayed using the microbrowser integrated in the panel. Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/M936

Introducing the Altivar 32

A modular, solution-based variable speed drive, featuring a built-in logic controller and safety functions. Offering ratings from 0.18kW to 15kW, the Altivar 32 has been designed specifically for the control of motors in machines requiring a high level of safety and functionality. Features:

Discover more Download the Altivar 32 brochure plus a FREE copy of SoMove Software and explore the logic and safety possibilities today!

> >

Compact design for vertical or side-mounting.

Integrated Bluetooth® and communications with all major protocols.

Integrated safety and programmable logic functions for adaptation to specific application needs.

High density installation possibilities

Compact and shallow mounting (90° faceplate)

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APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

REDUNDANCY IN INDUSTRIAL NETWORKS PART 2

Glenn Johnson, Editor

Industrial ethernet

In Part 1 of this article we looked at standard methods of Layer 2 network redundancy that involve auto-reconfiguration of the network topology after a failure. This time we continue and look at redundancy methods that are fully redundant.

s we saw in Part 1 of this article, link aggregation, spanning tree protocols and MRP, along with a host of proprietary redundancy protocols, provide many options for configuring networks for automatic failover. Redundancy protocols can also be combined to further enhance network availability. Other methods of achieving redundancy (usually using proprietary methods) are dual-homing and ring coupling.

Dual-homing and ring coupling One example of redundancy techniques that are based on proprietary technology is dual-homing protocols, also known as redundant coupling protocols. They usually have a recovery time in the 200 ms range. Although they may be installed as the sole redundancy method, they are more typically used in tandem with other methods. They are used to give redundancy, or to connect ring topologies, to enable redundant links between rings or between other lower level networks and a higher-level network. All data runs through a primary link and, on failure, a backup link is opened. Usually, both the primary and secondary links connect with two separate switches in the lower level network so that there would be no single point of failure. For example, with redundant ring networks, one process area might be put into one ring while another process area would be configured into a separate ring, with all the information directed to a central control station or historian server (Figure 1). Each ring or process would be redundantly coupled back to the main or backbone network so that the flow of information would not be interrupted.

Zero recovery time technologies The Layer 2 redundancy methods we have examined so far have three basic weaknesses: 1. They provide redundancy at the switch/network level, but not right down to the end device. If the link between the end device and the switch should fail, then the device will be unable to communicate, the effect of which will depend on the device and the process. 2. They provide redundancy for links, but not for entire switches. If a switch fails, all devices connected to the switch become cut off. 3. They have a finite, and often not deterministic, recovery time, which may be a problem for some high performance applications. An example of an application where a slow or non-deterministic recovery time can be an issue is in substation automation. Intelligent Electronic Devices (IEDs) is the name used for the technology that has come to replace protection relays and other technology for high voltage circuit control. Today, many of these devices have ethernet interfaces and, in a typical substation environment, communicate

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with each other and the higher level SCADA system via ethernet using the IEC 61850 protocol. Under this protocol, sample data may be collected up to 256 times per 50 Hz cycle (or 12,800 times per second) and network latency is a significant consideration for network design, under normal operating conditions. These networks are also implemented in an environment where large surges and EMI bursts are commonplace. If it is intended that network failures be accommodated in the design, then the recovery time of standard redundancy protocols may not be fast enough to ensure no loss of important data. In order to overcome these three limitations, two new standardised technologies are available which allow for two independent paths between any two devices, providing complete communication redundancy. They are both specified in IEC 62439-3. The big advantage of both these protocols is zero reconfiguration time, guaranteeing the highest communication availability.

Parallel Redundancy Protocol Parallel Redundancy Protocol (PRP) is implemented in the end devices and two independent paths are configured to exist between these end devices. The two networks are completely separated and are assumed to be fail-independent. They can have the same topology or be completely different and can also internally implement previously discussed redundancy protocols. The end device does not need to be â&#x20AC;&#x2DC;awareâ&#x20AC;&#x2122; of any of the features of the networks themselves (Figure 2). A source node with PRP functionality simultaneously sends two copies of a frame, one over each of two ports. The two frames travel through their respective separate networks until they reach a destination node, in the fault-free case, with a certain time skew. The destination node accepts the first frame of a pair and discards the second, taking advantage of a sequence number in each frame that is incremented for each frame sent. The result is that, as long as one network is operational, the destination always receives one frame. This protocol provides a zero-time recovery and allows the redundancy to be continuously checked to detect failures. The only inefficiency in this design, however, appears to be that the redundancy control information is late in the frame and the message has to be processed in order to determine if it is a duplicate. For PRP to work it must be implemented in software in the end nodes - the switches are standard devices and do not need to have any PRP functionality. An end device with PRP functionality is a Double Attached Node (DAN), having a connection to both networks. A standard device with a single network interface (a Single Attached Node, or SAN) can only be attached to one network.

APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

Industrial ethernet

Figure 1: Dual-homing and ring coupling may be used if these protocols are supported by the switches.

Figure 2: An example of a a redundannt configuration using PRP. The redundancy box acts like a redundancy proxy for the SANs attached to it.

Such a device has no redundant path in the event of network failure between it and another SAN. A device called a Redundancy Box (RedBox) can be used, however, to connect standard devices (or networks of standard devices) to both networks. In many implementations, only the critical devices need be DANs, while non-critical devices can remain as SANs or be connected through a RedBox. The RedBox implements the PRP for all the SANs attached to it as a type of redundancy proxy. This system works seamlessly provided both networks do not experience a failure at the same time. Availability can be enhanced further by implementing standard redundancy protocols within the two networks, independently. If we overlook the cost disadvantage of duplicated network hardware, the main cost advantages of PRP are: • Static redundancy reduces network engineering costs • The lower likelihood of network outages reduces operational costs • The use of standard ethernet hardware • Critical and non-critical systems can exist on a single network, rather than having to implement separate networks.

36 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

High Availability Seamless Ring High Availability Seamless Ring (HSR) is implemented in a ring topology with DANs connected to each other in a ring without dedicated ethernet switches. Nodes within the ring must be HSR-capable switching nodes. HSR works by passing the frames around the ring in both directions at once, resulting in a halving of the available bandwidth. Unicast frames, when received by the destination node, are removed from the ring and the data passed up to the application on that node. Multicast and broadcast frames, when received, will be forwarded on the other ring port. The sending node is responsible for removing the frame when it has traversed all the way around the ring, to avoid frames circulating forever. General purpose SANs cannot be attached directly to a HSR, except via a HSR RedBox (Figure 3). The advantage of HSR rings is that, like PRP, there is seamless failover. Unfortunately, being a ring topology, it cannot recover from multiple failures in a single ring. Being implemented in hardware, its application is in high-speed networks that require instant redundancy for a single failure, such as in substation networks and motion control.

Industrial ethernet

WITH THE COMING AVAILABILITY OF PRP AND HSR, IT WILL BE POSSIBLE TO IMPLEMENT ZERO-CHANGEOVER FAULT-TOLERANT NETWORKS ARCHITECTURES.

Figure 3: A typical HSR configuration. Single attached nodes cannot be connected directly to the ring as in PRP.

Figure 4: An example of mixing HSR and PRP in a redundant network.

There have also been concerns raised in some quarters that the fact that all traffic must go through all devices (twice) means that, in large implementations, the network speed may need to be more than 1 Gbps. The use of specialised hardware interfaces allows the upper-layer application and protocol stack to be ‘unaware’ of the underlying redundancy topology, but the disadvantage of this is the necessity for this specialised hardware. PRP, on the other hand, does not require specialised hardware as it still uses standard ethernet switching technology. PRP’s overall performance however is dependent on the standard networks it is implemented over. But, like PRP, HSR provides other cost benefits: • Static redundancy reduces network engineering costs • The lower likelihood of network outages reduces operational costs • Critical and non-critical systems can exist on a single network, rather than having to implement separate networks. HSR also defines a double RedBox known as a ‘QuadBox’ that can be used to link HSR rings together. Complex topologies, including ‘rings of rings’ can be implemented. HSR rings can also be maintained only for the high-speed critical parts of the network (such as for networks of IEDs in substations) and be connected via a RedBox

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to a standard RSTP or MRP redundant network as a backbone, or even to a PRP network using two RedBoxes - one for each of the two PRP networks. Figure 4 shows an example of mixing HSR and PRP in a redundant network.

Conclusion In today's automation applications, RSTP and MRP are the redundancy control protocols typically used, or alternatively a range of proprietary protocols (see breakout box). Most, if not all, industrial ethernet switches have RSTP and MRP redundancy control protocols implemented and have proved their worth. These protocols cover most requirements, but there have always been applications that cannot tolerate a failure of even a few milliseconds. Until now there has been no effective way to overcome this problem. But now, with the coming availability of PRP and HSR, it will be possible to implement zero-changeover, fault-tolerant network architectures. However, both PRP and HSR are very new. While PRP is already in use in some applications, HSR is still very new and is dependent on the development of equipment with HSR interface hardware.

APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

NEW PRODUCTS

NEW White Papers

COMPACT RTU Semaphore has announced that the T-Box LT RTU (Remote Terminal Unit) product line for remote monitoring and SCADA system applications has

now available online!

passed operations testing at -40°C. The T-Box LT is a compact, rugged platform with up to 32 I/O points.

Alarm rationalisation

Integral communications include ethernet, RS-232, RS-485 two-wire and

Alarm rationalisation is a systematic process to evaluate potential or existing alarms, qualify which are legitimate, specify their design and capture rationales which can be used to guide operator response. This paper describes the SILAlarm solution and other tips for setting up and sustaining an effective alarm rationalisation process.

a choice of PSTN modem, GSM/ GPRS modem, GSM 3G modem, spread spectrum radio or RS-232 with full modem control. T-Box employs a decentralised architecture that enables the

Oxygen measurement on air separation plants Industry consumes vast quantities of oxygen and nitrogen annually, all of which is obtained from the air around us. There are two main techniques used to separate these two primary gases from air. These processes are cryogenic separation and pressure swing adsorption (PSA).

complete integration of programmable automation, alarm management, data logging and IP telemetry in a single package, Semaphore claims. Platforms leverage web technologies and push messaging via e-mail, SMS text and FTP. The easily configured T-Box products are suitable for a range of monitoring and control applications in the asset management, broadcast/telecom, oil and gas, power,

8 steps to validating/mapping a chamber Periodic mapping of conditions within environmental chambers is critical for compliance in FDA-regulated applications, where validation of conditions such as temperature, and sometimes humidity, is mandated. This application note details the eight steps users should follow to ensure good manufacturing practice.

transportation, water and wastewater industries. CSE-Semaphore Pty Ltd Contact info and more items like this at wf.net.au/N002

MACHINE-MOUNT IP67 POWER SUPPLIES Balluff’s IP67 intelligent

Four ways to save energy in your drive automation

power supplies are de-

With today<0x2019>s soaring energy costs, it is important for industry to reduce energy consumption wherever possible. Electric motor-driven equipment accounts for almost 65% of electricity consumed in the manufacturing sector, meaning improving the efficiency of motor and drive systems is a major consideration for cost cutting.

signed to mount directly on machines such as conveyors, and with Balluff’s Heartbeat technology maintenance crews get feedback on the real-time and long-term status of the supply to enable prediction of the replacement and maintenance cycle of the supply. They offer greater than 93% efficiency and can provide power boost of 150% for up to 4 s. Being mechanically durable to vibration and shock, they are deisgned for a minimum service life of 15 years. Balluff-Leuze Pty Ltd

For these and more White Paper downloads, visit www.processonline.com.au/white_papers

38 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

Contact info and more items like this at wf.net.au/N162

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NEW PRODUCTS

ENCLOSURE COOLING Rittal’s energy-saving ‘Blue e’ enclosure cooling units offer a cooling output ranging from 500 W to 4 kW (depending on the application) and are claimed to achieve energy savings of as much as 70%. In terms of size and appearance, the Blue e cooling units are similar to Rittal’s TopTherm system, but with a 42% higher coefficient of performance (COP) - up from 1.2 to 1.7. The efficiency of the cooling units is firstly related to the design of the condensers, evaporators, cooling fins, pipe bends and all the other refrigeration components. Rittal also optimised the fan technology. Electronic commutation (EC) technology is used in most of the fan motors. In these motors, designed as external rotor motors, the traditional mechanical pole reversal is replaced by electronic commutation, which functions without wear, sparks or interference. The motors have a dynamically balanced rotor with multipolar magnets. The rotor position is recorded by several Hall effect sensors. Motor supply and control is via an external electronic operating system that has a high efficiency at all speeds. Precision bearings provide a long service life and low noise generation. Rittal has improved the control electronics by means of new Eco-Mode controls. If an internal fan does not need to operate permanently, it is automatically switched off, so cutting energy costs. Rittal Pty Ltd Contact info and more items like this at wf.net.au/N181

WIRELESS AP/BRIDGE WITH M12 CONNECTORS Strong vibrations, moisture and dust created by industrial machinery can cause data connections to become loose. Where a network device is connected to the control centre via a wireless link, an unstable wired connection between the device and the wireless access point impedes the efficiencies gained by wirelessly accessing the equipment. Created specifically for applications where strong vibrations can cause networking problems, the AWK-3131-M12 from Moxa provides the secure reliability of M12 connectors and protect wired connections from the inevitable wear and tear of vibration, moisture and dust. The AWK-3131 is Moxa’s basic indoor wireless access point/client/bridge that is built to the 802.11n standard, making it backwards compliant with 802.11a/b/g. The entire device is housed in a sturdy IP30, full-metal casing and features Power over Ethernet+, redundant power jacks and Turbo Roaming to provide a wireless connection that can reach data transfers of 300 Mbps and roaming handoffs as quickly as 50 ms, when paired with other Moxa hardware. MIMO technology icreases data throughput (up to 300 Mbps) and range. The AWK-3131-M12 also has an operating temperature range of -40 to 75°C. Madison Technologies Contact info and more items like this at wf.net.au/M995

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PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

Process Technology Regional Roadshow

2012 8

NOW IN ITS TH

YEAR

vend NEW or sess training ions

Queensland Coming soon ... to a city near you!

If you work in mining, minerals, metals processing, utilities, food and chemical manufacturing and processing then the Regional Roadshows are designed for you. Don’t miss out ...

NEW TRAINING SESSIONS FOR 2012 • Tune a PID flow loop • Troubleshoot a simple TCP/IP industrial ethernet network using four simple utilities • Write, install and test a motor control PLC ladder logic program • Basics of Modbus data communications protocol installation and troubleshooting • Arc flash protection and protective safety equipment • Variable speed drives— testing and troubleshooting

Brisbane • May 14 Gladstone • May 15 Mackay • May 16 Townsville • May 17

Supported by:

Training by:

Exhibiting companies include:

Includes FREE: • Access to exhibition • Training sessions - NEW • Lunch and networking drinks • Product demonstrations • Prize draws

To register or for more info visit: www.regionalroadshows.com.au

AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289)

NATIONAL OHS HARMONISATION: WILL IT ARRIVE?

Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

s I travel around the countryside meeting many of our customers and discussing all of the things that are currently affecting their businesses, one of the things I am often getting asked about is the current state of the national harmonisation of OHS laws. Usually the conversation covers the socalled ‘patchwork’ or ‘two-speed’ economy with mining and professional services showing double-digit growth while manufacturing and agriculture are lucky to be in positive territory. Add into that the uncertainly around the true impact of a carbon tax on a number of businesses, coupled with concerns about the challenges employers see with the flexibility of the current Fair Work Australia laws, and employers are finding it challenging to position their businesses for the future - not to mention to attract and retain staff amidst the lucrative offers from the mining industry. And then there is a high Australia dollar that looks like staying at these levels for at least the near future - meaning our home-grown manufacturing is doing it tough when compared with offshore goods. Little wonder some of our customers are not too optimistic about the future. However, one small ray of sunshine was the national harmonisation of the OHS laws, especially for larger national corporates, as it promised reduced administrative costs and greater economies of scale. Streamlining the different state OHS compliance requirements and creating nationally consistent safety standards should lead to greater certainty and understanding of OHS laws and ultimately, better safety outcomes for all businesses. The harmonisation deadline set by COAG in 2008 was 1 January 2012, but that deadline has well and truly passed with us seemingly no closer to the desired end state. With Queensland, New South Wales, the two territories (ACT and NT) as well as the Commonwealth passing the laws, we still have four states yet to enact the changes. Both South Australia and Tasmania are both trying hard and may

Janette Woodhouse

introduce the legislation in the near future as the bills go back and forth within state parliament. However, Victoria and Western Australia have absolutely no urgency, as the legislation seems to be a fair way off while both governments talk about the significant time needed to further assess its impact on their state. At a time when there are many complexities involved in creating a safe workplace - the technicalities of machine and plant safety, enacting behavioural safety and culture change programs, stimulating workforce ownership and safety leadership, as well as all the OHS compliance requirements - the last thing businesses need is a confusing legislative framework. After significant time and effort we are no closer to harmonisation and we will be lucky to see anything by 2013. Unfortunately, it is the safety of our people and workplaces that will ultimately suffer and in my travels I have seen a number of companies that desperately need all the help they can get - and with the majority of their time and effort focused on the other issues above, safety is not getting the attention it deserves. I urge the government to put politics aside and fast track the harmonisation so companies can get on with the job of running their businesses safer than ever before.

A formally trained chemical engineer, Scott Moffat is the Managing Director of Pilz Australia & New Zealand. He is a senior executive with over 20 years’ experience and extensive knowledge in the automation, safety, energy, mineral processing and petrochemical industries and possesses a unique blend of engineering background and corporate finance coupled with strong business acumen and customer focus.

42 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012

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Sept 2011 total CAB audited circulation (Aust + NZ) 7,451 readers (92% personally requested)

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Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP255003/00198 ISSN No. 0819-5447 All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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