What’s New in Process Technology Feb 2012

0212

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2012

Endress+Hauser’s Levelflex family provides

CONTENTS

precise measurement of levels and inventories in process applications using guided radar technology.

The innovatively engineered Levelflex FMP54 is specially designed for the most demand-

4

Securing the benefits of integrated networks

ing level measuring tasks in the oil and gas,

Converging plant and enterprise networks introduce new risks

chemical, and power industries. Typically, these measurements require solutions for

8

New products

high temperatures and high pressures and

16

Hot products online

to operate in process temperatures up to

20

Corrosion monitoring

Breaking down the misconceptions

32

Background suppression photoelectric sensors

both in high temperatures and pressures such

Ten key steps in selecting and using them

as those that occur, for example, in steam

42

As I see it Informal training is the most powerful form of engineering education

the FMP54 is a good match with its ability 450±C and pressures up to 400 bar.

The design of the process connection with its ceramic-graphite seal safeguards processes

boilers and toxic media applications. The second gas-tight feed-through provides additional safety at the process connection point.

In high-pressure applications the density of the gas phase is drastically increased, causing changes in microwave run time.

These changes cause conventional guided radar instruments to perform unreliably and present risks to process safety.

The gas phase compensation offered in the Levelflex uses a special reference reflector to dynamically correct for this condition to provide reliability and precision of measuring results.

The Levelflex range, in particular the FMP54, is also popular as a ‘displacer replacer’ for legacy mechanical methods used in bypass chambers or bridles, as it eliminates the high maintenance and measurement drift that these mechanical systems are prone to.

Levelflex offers more than merely a measured value.

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

http://www.processonline.com.au/latest_issues

Endress+Hauser Australia Pty Ltd www.au.endress.com

SECURING THE BENEFITS OF INTEGRATED NETWORKS Gordon Bartlett, Rockwell Automation

4 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

I

ndustry is rapidly seeing the benefits of integrating the many facets of process and enterprise functions into a unified system. In the past, individual processes across the plant floor used proprietary or separate networks, isolated from enterprise business applications, which often led to the doubling up of information and resources. The aim of an integrated system is to merge the multiple disciplines of process and automation (continuous process, batch, discrete, drives, safety and motion) into a single, streamlined network that can be centrally administered in conjunction with the business network. The advantage of an integrated architecture for many companies is shown through increased productivity as assets are better utilised and information is accessible in real time.

Transparency through standardised information presentation also allows monitoring of resource usage to help provide energy consumption and emissions consistent with business KPIs and commitments to sustainability.

The uniformity introduced by an integrated architecture allows additional processing devices to be added with relative ease. Scalability of the system is now manageable and development time for new hardware or processes is reduced, so that businesses now have a degree of flexibility not previously available with disparate system configurations.

Networks and security The key to successfully integrating the architecture is in the underlying network. The deployment of ethernet is being taken up at

www.ProcessOnline.com.au

a rapid rate due, in part, to the familiarity and usage at the enterprise level. Many companies are using standardised unmodified ethernet as the basis for this architecture, and the use of open protocols makes complex automation control integration easier as it requires fewer steps to accomplish connectivity of device and application.

It is recognised that enterprise networks provide a door to the outside world via the internet and, as such, expose the company to a greater risk of intrusions from viruses and malware. Connecting the plant floor through the same network can now potentially make the entire company vulnerable to the same threats.

The application of security procedures is designed to minimise the risk of malicious external attack, but unintentional security issues from within the company should also be addressed when considering security. The potential for breaches are typically the result of a lack of attention to standard operating procedures and poor training or accidents, and account for the majority of problems encountered.

Locking the door to the server room is not sufficient if network access is available from any computer via a default password.

Equally, changing the recipe for the company’s bestselling product should not be possible via the computer at reception. Solutions such as locking doors on network infrastructure cabinets, maintaining software updates and backups, and restricting access, both physically and electronically, are simple measures that should be addressed by standard operating procedures.

Š iStockphoto.com/kyoshino

Converging plant and enterprise networks into an integrated architecture is rapidly gaining ground in industry as a means to providing a method of uniting multiple control disciplines into a single cohesive plant-wide system. However, the use of ethernet to facilitate integration may expose the company to an increased level of risk. Gordon Bartlett, Architecture & Software Business Manager South Pacific for Rockwell Automation, discusses the current approach to integrated architecture security.

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Network security

AS WITH MANY COMPANY-WIDE STRATEGIES, THE SUCCESS OR FAILURE WILL BE DEPENDENT ON TRAINING, MONITORING, MAINTAINING AND VALIDATION. THE MOST SOPHISTICATED SECURITY MEASURES WILL NOT WORK IF PASSWORDS ARE NOT REGULARLY UPDATED, ACCESS DOORS ARE LEFT WEDGED OPEN, USB DEVICES ARE NOT AUTOMATICALLY SCANNED FOR POTENTIAL VIRUSES,

Figure 1: The ‘onion model’ describes the strategic defence-in-depth approach to ensuring that security covers all aspects of plant and enterprise.

In recent years, there have been several high-profile incidents, such as the security breach recently experienced by Sony in regard to credit card privacy via the PlayStation platform. The company has certainly suffered as a result of the breach. Additionally, the recent discovery of malware that specifically targets industrial control systems has brought industrial security to the forefront in manufacturing.

As a result, there is growing recognition of new risks and real-world threats that are capable of disrupting control system operation and adversely affect safety, productivity and the ability to adequately help protect assets, machinery and information alike.

The potential for disastrous outcomes from malicious attacks has prompted some government agencies in the USA, for example, to take a more proactive approach to security and managing risk, and to identify critical infrastructure industries in the USA that pose a heightened risk to the public if under attack. The emerging industrial security standards from the International Society of Automation (ISA-99), the National Institute of Standards and Technology (NIST 800-82) and the Department of Homeland Security (INL/ EXT-06-11478) all recommend two principle strategies to cover the many facets of security for plant and enterprise: defence-in-depth and DMZ deployment (structuring the network into manageable levels and zones).

Defence-in-depth Often described as the ‘onion model’ due to its schematic representation, defence-in-depth

AND SOFTWARE IS NOT EMPLOYED TO ONLY ACCEPT ‘KNOWN’ USB DEVICES.

strategies break down the various aspects of security into five core layers.

The outer skin represents physical security and deals with tangible aspects such as limiting entry to server rooms to authorised personnel, locking control panels and cabling, and the tracking and escorting of visitors.

Firewalls, secure switches and routers form the backbone of the second layer network security. It is here the underlying infrastructure framework is protected with intrusion detection and prevention techniques.

Many security measures fail due to mismanagement of software updates, including antivirus applications, particularly at remote sites. For instance, head office has the latest updates for enterprise applications while the offsite office is still running a version that has been superseded. The risk in this scenario is that the improved security features that are available in the most recent upgrade are not applied elsewhere, but both are still connected via the same network infrastructure, creating potential ‘holes’ in the security blanket. It is here - computer hardening - that the third layer of the onion model takes effect. This strategy can help ensure that all sites are running the same versions, that they have been fully tested prior to implementation, and unused or redundant applications, protocols and services are removed.

The fourth layer, application security, provides authentication, authorisation and audit software, restricting users according to their access level and training. Many industries that rely on batch and ingredient control, need

6 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

to provide a method of recording activity around a process, such as who changed the ingredients, when it occurred and who authorised the change. These records need to be logged and regularly audited, which can help ensure that no breaches are made - intentional or otherwise.

The most internal layer of defence-indepth deals with device hardening - protecting the actual controllers, drives, motors, valves and other automation and control devices from intrusion and security breaches, and applying change management and disaster recovery procedures.

Zoning the network The defence-in-depth strategy gives a systematic approach to security from one end of the business to the other, but does not provide a comprehensive framework for protecting the information flow throughout the network. The ISA-99 approach establishes a Manufacturing Network Security Framework, allowing the overall plant and enterprise network to be broken into levels and ‘zones’. Each ‘zone’ is defined as an aggregation of resources with similar processes, access requirements, risk points and security strategies. For example, enterprise functions such as email, intranet, planning and logistics are grouped into the ‘Enterprise Zone’. The manufacturing zone will contain the plant-floor operational hardware and software such as production control, process history and other decision-making tools for production. The final zone, the ‘Cell Zone’ is a subset of the manufacturing zone

www.ProcessOnline.com.au

Network security

Figure 2: Conceptually, the company network is broken into levels based on complexity, operational behaviour and security risk. The use of the demilitarised zone provides the plant floor with a security buffer to the enterprise network.

and contains operator interfaces, batch and discrete controllers, sensors, drives, actuators and robotics.

A fourth and crucial zone exists between the Enterprise Zone and Manufacturing Zone, known as the demilitarised zone (DMZ).

Acting as a buffer zone between enterprise and plant, it enforces security strategies on information passing between the two networks. Information cannot communicate directly between enterprise and plant and must terminate or originate in the DMZ. A key component to facilitate the effectiveness of the DMZ is a firewall on each side.

Effective security strategies As with many company-wide strategies, the success or failure will be dependent on training, monitoring, maintaining and validation. The most sophisticated security measures will not work if passwords are not regularly updated, access doors are left wedged open, USB devices are not automatically scanned for potential viruses, and software is not employed to only accept ‘known’ USB devices. Many of the security breaches that occur daily do not always originate from outside sources - many are due largely to poor personnel practice and procedures. Training staff on security policies and procedures must be incorporated into the whole business infrastructure if it is to be successful.

The implementation of security measures raises some valid concerns, particularly security of devices sourced from suppliers

www.ProcessOnline.com.au

and validation of their operation. Ongoing collaborations between companies such as Rockwell Automation and Cisco Systems continue to develop and provide validated equipment that is compliant with the guidelines and standards derived by ISA, NIST and DHS. Implementation and maintenance strategies are therefore integrated into automation supplier products and services, whether it is for ethernet or some other proprietary network or protocol.

Companies must undertake risk assessments and estimate the probability of a security breach to determine the level of protection required in proportion to the critical nature of the control or process.

The use of firewalls, patch management strategies, business continuity plans, intrusion detection and protection systems will need to be implemented across the plant.

The level of security an individual process may require is dependent on the perceived damage a security breach may cause. Deciding what course of action should be taken in the event of a security breach will also need to be considered.

It is the responsibility of both the IT and engineering departments to ensure that all facets of the security strategy are in place and up to date. Protection of the plant, based on perception of acceptable risk, will need to be in accordance with company policy and industry standards. Evaluation of the security system is achieved through auditing, monitoring and re-evaluation of all components so the whole system is adequately maintained

in order to deal with current threats and also have the ability to respond to the threat.

As automation and processing systems move away from isolated components of processing and enterprise, to operate over a single plant-wide network environment, the level of risk for security breaches increases.

To implement, manage and maintain a successful security system is to recognise the potential hazards, assess the risk and determine the security required and gauge the impact on business operations if a security breach occurs.

Integrating security into the overall network architecture will greatly enhance the ability to apply security measures across all facets of both plant and enterprise. Using strategies such as defence-in-depth and zoning (creating a DMZ) help ensure that not only are devices such as switches secure, but management can be confident that their business is meeting the standards and recommended practices to comply with regulatory bodies.

To successfully implement a security system is to establish corporate strategies and policies so all personnel are trained in its use and application. Maintaining and monitoring the system can help the system operate with minimal impact of known security risks, both internal and external, as well as having the capability to help protect against new threats.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/P236

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

MULTICHANNEL DAQ SYSTEM The TMR 200 data acquisition system from TML, Japan, is a compact multichannel data acquisition system that enables the use of a combination of various sensor inputs according to measurement purpose.

A high-speed sampling rate of 100 kHz is possible and sensor input units include not only analog I/O for strain, voltage, temperature, etc. but also digital I/O for CAN, voice/GPS and a telemetry interface unit.

Up to 80 channels can be used at any one time.

Real-time histogram analysis (option) as well as waveform recording is available. The colour LCD unit makes data acquisition possible without a computer, while interfacing with a computer allows for more sophisticated histogram analysis.

The vibration tolerance of the system and its small size make it suitable for use on board a vehicle. Battery operation is also possible, as is data recovery at power interruptions and measurement restart at power recovery.

The data acquisition system is compatible with large-capacity CF cards, and the data acquisition system also has USB and LAN interfaces.

Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/L953

IP67 SMART CAMERAS The NI 177x range of smart cameras features a 1.6 GHz Intel Atom processor for increased processing power and an IP67 rating to protect the hardware from dust and water. The cameras also have a real-time operating system to deliver the reliability and determinism needed on a production floor.

Using the Intel Atom processor, the 177x range can deliver processing speeds four times greater than previous models.

They also have updated sensor options, including VGA, 1.3 MP and 2 MP in colour and monochrome as well as 5 MP in monochrome. A strong mechanical housing, M12 connectors and lens cover make the cameras dust and water resistant and suitable for environments with washdowns.

The cameras include four digital input and four digital output lines and support several industrial communication protocols including RS232 (serial, Modbus serial) and ethernet (TCP/IP, EtherNet/IP, Modbus/TCP). The cameras also include a VGA video out connection for monitoring inspection images.

The NI 177x smart cameras are shipped with NI Vision Builder for Automated Inspection (AI) 2011 software, a menu-driven, interactive environment for configuring, benchmarking and deploying vision systems. The cameras can also be programmed using NI LabVIEW graphical programming and the NI Vision Development Module for advanced customisation and integration with other National Instruments hardware.

National Instruments Australia Contact info and more items like this at wf.net.au/L830

DUAL-MEMBRANE PH ELECTRODE The InPro 4850i inline pH electrode is designed specifically for the requirements of the chloralkali industry. The electrode incorporates a sodium-sensitive glass membrane that uses the brine present in chlorine production as a reference. This reference system is hermetically sealed, providing a barrier against oxidising agents.

The electrode does not have a diaphragm, therefore poisoning of its sodium reference system is impossible. This design ensures stable measurement and eliminates sensor drift.

It also uses Mettler Toledo’s intelligent sensor management (ISM) technology that converts the analog measurement signal into a low-impedance digital signal that is immune to electrical interference, ensuring 100% signal integrity and stability. ISM technology also offers sensor self diagnostics, precalibration of sensors and plug-and-measure start-up to simplify installation and maintenance tasks.

Mettler Toledo Contact info and more items like this at wf.net.au/L957

8 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

Save The Date & Register Now!

Join us at “Rockwell Automation on the Move” presented by Rockwell Automation in collaboration with our PartnerNetwork™ companies.

MELBOURNE • March 6-7 Melbourne Park Function Centre Olympic Boulevard (formerly Swan Street), Melbourne

We are pleased to announce that Rockwell Automation on the Move will be touring Melbourne, Sydney, Brisbane and Perth.

SYDNEY • May 2-3 Sydney Showground 1 Showground Road, Homebush

Learn how smart, safe and sustainable manufacturing practices can turn your marketplace challenges into advantages.

Take advantage of automation expertise from Rockwell Automation and our PartnerNetwork™, providing you with a comprehensive set of industry leaders in distribution, systems integration, machine building and complementary technologies.

Mark your calendar to join us. For more information visit...

BRISBANE • May 22-23 Brisbane Convention & Exhibition Centre Cnr Merivale & Glenelg Streets, South Bank, Brisbane PERTH • June 6-7 Burswood Entertainment Complex Great Western Highway, Burswood

www.rockwellautomation.com.au

The Smart, Safe, Sustainable Advantage Enable Plant-wide Optimisation Helping you get more productivity and efficiency from your automation investments throughout all stages of your plant’s lifecycle.

Boost Machine Builder Performance Flexible, scalable automation solutions designed to lower Total Cost to Design, Develop and DeliverSM machines and improve overall performance.

Drive Sustainable Production Increase competitiveness and overcome the rising costs of energy, raw materials and lost worker productivity.

Safety Automation Forum This “event within an event” will showcase Rockwell Automation users as they share best practices and demonstrate how they deploy successful safety programmes. There will also be sessions on safety technologies and the latest standards. Melbourne and Sydney events only.

NEW PRODUCTS

RADIATION-BASED BELT WEIGHER WeighTrac is a radiation-based sensor for precise determination of the feed rate of bulk solids. It measures contactlessly with the help of gamma radiation and is suitable for mass flow measurement on conveyers. Its frame construction allows simple installation and retrofit.

WeighTrac is the radiation-based alternative to mechanical belt weighers: it delivers the current flow rate as well as the summed throughput of bulk solids on conveyor belts or in screw conveyors. The radiation-based measuring method detects material flow reliably, even on wide conveyor belts.

WeighTrac can also be retroactively installed on existing conveyance systems without great effort.

Radiation-based flow rate measurement is based on radiation absorption by layers of bulk solids - these attenuate the

SAFE I/O MODULE

gamma radiation in proportion to the quantity and density of the material. WeighTrac calculates the

The 0942 UEM 612 I/O module from Lumberg Automation is

mass throughput from the intensity of

designed for use with the LioN-Link decentralised Fieldbus

the incoming radiation and the speed

system. It fulfils protection class requirements IP67 and has

signal from the tachometer.

four digital M12 slots with a higher limit on the output voltage,

The Vega plics instrument concept,

permitting 2 A per line and 6 A in total. These outputs are

in conjunction with WeighTrac, makes

designed for safety-related applications up to performance

setting up and operating a flow rate

level D, making this I/O module suitable for failsafe control

measuring system simple. Setup and

of actuators or - following a complete switch-off of the

commissioning of the system is easily

24 V output power supply - reliable emergency OFF functions.

carried out on a PC with the help of DTM/

Terminal equipment can be connected directly to the I/O

FDT technology supported by intuitive

module so there is no need for terminal boxes, which

menus and intelligent assistants. As an

are comparatively expensive and complicated to install.

option, the indicating and adjustment module PLICSCOM

This makes it possible to implement cost-effective safety

can be used for on-site indication of the measured value.

solutions that can be used, for example, in mechanical engineering applications or in the assembly and handling sector.

Depending on the selected LioN-Link bus coupler, this I/O

VEGA Australia Pty Ltd Contact info and more items like this at wf.net.au/L709

module can be used in ProfiNet, Profibus, DeviceNet or CANopen networks. Setup of the modules is simplified because LioN-Link systems do not use slave address assignments and do not require terminating resistors. The sturdy housing measures 182.4 x 30 x 28.4 mm (L x W x H) and weighs 200 g. The module’s other features include a temperature range of 10-60°C, high vibration and shock resistance and a power supply configured for a voltage range of 19-30 VDC. Belden Australia Pty Ltd

STRAIN-GAUGE AMPLIFIER

Contact info and more items like this at wf.net.au/L899

Futek Advanced Sensor Technology has released its upgraded CSG110 straingauge signal amplifier. 95% of the amplifier’s parts have been revised, reducing noise output, increasing bandwidth and implementing co-amps.

The amplifier is now CE approved to the highest criteria, making it compliant for all medical, industrial and consumer applications.

Output noise has been reduced to ten times less than that of the previous model. Short-circuit protection has also been added and DIP switches have replaced the soldering of the internal components, making the CSG110 free of any lead-based materials and therefore RoHS compliant. This 1 or 10 kHz amplifier has the option of being modified to support 25 kHz. Metromatics Pty Ltd Contact info and more items like this at wf.net.au/L964

10 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

Some people don’t understand the importance of selecting a high performance control valve in their process plant. We do.

Some people think that all valves are created equal. We don’t.

Some people think that buying all valves from the one company, makes better business sense. Most of the time, it doesn’t.

Some people think that they’re getting good service. For most of the time, they’re not.

Maybe you don’t know of us very well, even though we’re a 100 year old, wholly owned Australian Company.

And we have the experience and willingness to show you how a well-engineered valve, will provide you with better plant performance.

With significant cost savings. We’re great to do business with and we offer great service. Don’t settle for less. We don’t.

Best in Class Products. Highly Experienced Engineers. Always Striving to be Better.

For more information call Austral-Powerflo National Hotline 1300 658 701 SYDNEY BRISBANE MELBOURNE PERTH AUCKLAND NOUMEA

Nanofiltration increases water production capacity at beverage plant A six-month project, completed by Ovivo Australia in just 12 weeks, has enabled two large beverage companies to increase their production capacity by 420%.

The joint venture between Frucor NZ and Slade’s Beverages in Thomastown, Victoria, was to increase the production of water supply by installing a nanofiltration system. This has allowed for the production of a new range of V Energy drinks and other products using water directly from the potable supply.

The client required a 30 m3/h supply of consistent quality demineralised water to ensure that flavours were not affected. The nanofiltration system was recommended by Ovivo Australia due to its small filter pore size which is fine enough to remove contaminating flocculants and divalent metal ions.

The process, designed to take feed water from Melbourne’s potable water system and treat it to remove fine flocculent particles and dissolved metal impurities, was completed

by Ovivo Australia with the support of VanDer-Molen GmbH, a member of the Ovivo water group.

The integrated nanofiltration plant and permeate transfer system was delivered at the end of May 2011. As well as removing the impurities, the system also allows for a consistent quality of product water in terms of hardness, TDS and pH. This enables the client to accurately control the flavour as well as the carbonation process in soft drink making.

Analysis of local potable water samples showed TDS levels of 100 mg/L. The system was designed to reduce these to less than 55 mg/L and maintain a consistent pH of 6.2 to 6.5. The system was also designed for an 82-85% recovery of the potable water feed utilising a 3-stage, single-pass treatment process.

The nanofiltration plant utilises mains water pressure to feed through a pretreatment process which involves PID controlled dosing of antiscalant and SMBS for membrane protection. Additional cartridge filtration prior to the NF plant is in place to protect against particulates from depositing on the membrane.

A 15 kW vertical multistage pump drives the

36 m3/h feed to the required pressure to push the water through the membranes.

The generated permeate is maintained below an 80 µS/cm conductivity setpoint by a discharge conductivity meter. Permeate which is above this limit is discharged to sewer via an off-spec valve to maintain a consistent quality product in the permeate tank. The permeate is stored in a product tank being delivered to the client’s processes via two VSD controlled centrifugal pumps. An integrated recycle system is implemented to allow delivery of permeate from the product tank back to the nanofiltration plant for use in the CIP process.

As the feed water is potable water, the discharge TDS on the brine side is extremely low. TDS levels in the discharge are only 370 mg/L with a pH of 7.8, which has meant the water can be recycled.

Ovivo provided an online quality control system to ensure all water delivered was within the 85 µS/cm quality specification.

The integrated control system means the plant operates as a self-contained turnkey plant and HMI software includes a CIP procedure walkthrough feature to remove the risk of operator error during membrane cleaning.

12 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

As well as the challenge of meeting a 12-week delivery schedule, Ovivo Australia faced a second test of having to increase the package size when product storage was added to the project scope and delivered with just four weeks remaining. An integrated automatic product transfer pumping solution, including three pumps and a secondary VSD control panel and upgrades to the existing NF control panel, were also added to the scope and delivered within 10 days.

There are a number of benefits of nanofiltration over a reverse osmosis system.

Nanofiltration uses a small enough filter pore size to remove contaminating flocculants and divalent metal ions, and the water quality still contains vital dissolved salts so that it does not require significant remineralisation for human consumption. The energy required per unit of product is lower and there is lower capital expense in implementation. Also, the product water, due to its high quality, can be used for both the manufacture of the beverage flavouring as well as the carbonated make-up water.

Ovivo Contact info and more items like this at wf.net.au/P239

www.ProcessOnline.com.au

NEW PRODUCTS

CUSTODY FLOW COMPUTER The FloBoss S600+ is a panel-mounted fiscal flow computer designed specifically for hydrocarbon liquid and gas measurement where versatility and accuracy are high priorities. It allows multistream,

SERVOMOTOR TERMINAL The EL7201 servomotor terminal for the EtherCAT Terminal system is designed for highly dynamic positioning tasks. It integrates a full servo drive including an encoder system into a 12 mm terminal.

The terminal is suitable for the direct connection of servomotors up to 200 W, and combining it with servo motors from the AM3100 series enables the implementation of an inexpensive servo axis. Due to the high torque and the high, stable speed, this drive solution is suitable for pick-and-place applications and for use everywhere that high dynamics, compact design and exact positioning are required.

The complete integration of the drive technology into TwinCAT automation software enables programming and configuration to be carried out conveniently in one tool. As a result, engineering is simplified and diagnostics are improved. TwinCAT PLC provides the user with a multitude of software function blocks which, due to their high degree of abstraction, can be applied to the different types of axis for a wide

multistation applications to be configured for simultaneous metering of gas, wet gas, crude oil, refined products, LPG and NGL. The computer has two full duplex high 100 Mbps ethernet ports and nine serial ports as standard, which provides greater metering and integration capability. With Coriolis and ultrasonic meters being increasingly utilised in the field, the S600+ has been designed to further enhance these metering technologies.

The extended data logging and archiving provides additional security and reduced operational costs for remote sites. In the event of a supervisory system failure, data integrity and audit trails are maintained.

The computer provides an in-built web server with improved security that allows for remote diagnostics, report access and configuration.

Emerson Process Management Contact info and more items like this at wf.net.au/L929

variety of functions.

Beckhoff Automation Pty Ltd Contact info and more items like this at wf.net.au/L405

www.ProcessOnline.com.au

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

NEW PRODUCTS

PRESSURE CALIBRATOR The Crystal nVision Pressure Calibrator 30 bar is an intrinsically safe NATA-certified pressure calibrator. It displays real-time recorded data graphically on a high-resolution screen and can be used to download the data during testing.

The pressure calibrator allows users to zoom and scroll within specific events to observe the repeatability and performance of pressure safety valves. The device also logs and displays 500,000 data points on two sensor modules simultaneously.

It comes configured with an MA20 current, voltage and switch test module and 30 bar pressure module, and includes a hand pump and CPF (finger tight to 700 bar) fittings. It is capable of ten readings per second and has an accuracy to 0.025% of reading.

The enclosure is IP67 rated.

DISTRIBUTED MODULAR I/O SYSTEM Balluff’s new generation of distributed modular I/O can be used in a cost-effective way to replace standard slice I/O and distributed I/O solutions. Offering IP67 protection and industry-standard connectors, many types of control data can be collected. Using standard 3-conductor cables, up to four slave devices can be connected to each master block, which communicates over the industrial ethernet network to

TechRentals Contact info and more items like this at wf.net.au/L956

the controller.

In lieu of a backplane, each I/O device is connected to an industry-standard M12 port, creating an IP67 connection.

With the ability to be installed within a 20 m radius from the

DSL PROFIBUS EXTENDER WITH SURGE PROTECTION

master device, slave devices can be easily distributed across

The DSL Profibus extender from

point technology, IO-Link, a distributed modular I/O system

Phoenix Contact is designed to enable

is fieldbus independent, easily configured and vendor neutral.

the machine. Utilising a widely accepted and open point-to-

straightforward integration of remote

Types of distributed modular I/O slave devices that are avail-

Profibus devices at data rates of up to

able include discrete I/O, analog I/O, valve manifold control,

1.5 Mbps. The extender has two DSL

industrial RFID processors and heads, and specialty sensors

connections per device. This means

for measurement, position or colour detection.

that, in addition to point-to-point con-

Industrial ethernet master blocks are available with EtherNet/

nections, the extender can also be

IP or Profinet protocols. EtherNet/IP masters support daisy-

used to establish line structures with

chain connections with a built-in switch as well as support the

up to 30 devices.

Device Level Ring (DLR) topology for easier troubleshooting.

To protect the communications modules, surge protection is required

Profinet blocks support Fast Start Up (FSU) as well as the

for both DSL connections. The DIN rail-mountable DSL surge protector

Link Layer Discovery Protocol (LLDP) for easy set-up right out

offers two a/b connections per screw terminal. When designing a line

of the box. Both master devices have easy-to-use, lockable

structure, users therefore need only one surge protector per intermediate

push-button displays for quick set-up and provide webpages

station, saving space in the control cabinet and lowering costs.

for configuration or diagnostics purposes.

Phoenix Contact Pty Ltd

Balluff-Leuze Pty Ltd

Contact info and more items like this at wf.net.au/L958

Contact info and more items like this at wf.net.au/P311

14 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

WIRELESS ACCESS POINT The APXG-Q5420 industrial wireless access point is de-

>

signed to enable M2M equipment to become the centre of a self-sufficient Wi-Fi network.

Interworld Electronics & Computer Industries

WF.NET.AU/L927

> SOUND AND VIBRATION SUITE The latest version of the NI Sound and Vibration Measurement Suite software provides a comprehensive collection of analysis and signal processing tools for

>

noise, vibration and harshness (NVH) testing, machine condition monitoring (MCM) and audio test applications.

National Instruments Australia

WF.NET.AU/L952

HIGH-TEMPERATURE PRESSURE TRANSMITTER The Keller Series 35X HTC pressure transmitter is primarily designed for hot media in biotechnology and food industry applications.

Bestech Pty Ltd

WF.NET.AU/P164

> > THERMAL DISPERSION FLOW SWITCH

WIRELESS REMOTE NETWORK MODULE

The Series TDFS thermal dispersion flow

The WNM wireless network module pro-

switch indicates whether the flow rate is

vides a low-cost wireless communications

above or below a user-set flow rate with

link between field sites that are in rugged

NO and NC NPN outputs.

or impassable terrain, at distances of up

Dwyer Instruments (Aust) Pty Ltd

to 48 km.

WF.NET.AU/P223

Moore Industries Pacific Inc.

WF.NET.AU/P246

16 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

Little on size, Large on performance Introducing the new L Series programmable controller

proven performance / global strength / cost effective solutions www.mitsubishielectric.com.au or call us on 02 9684 7777

NEW PRODUCTS

FANLESS PC WITH HAZARDOUS AREA APPROVAL Acromag’s rugged I/O Server industrial PC is now UL/cUL listed with approval for use in Class I Division 2 Groups A, B, C, D hazardous environments containing volatile substances.

Already ruggedised for computing in sites subject to extreme temperatures, shock and vibration, the Acromag I/O Server industrial PC now has Underwriters Laboratory (UL) certification for Class I Division 2 Group A, B, C, D hazardous locations with volatile substances. This UL approval permits use of the I/O Server fanless embedded computer and its plug-in I/O modules in environments with flammable liquids, gases or vapours.

UL’s Class I Div 2 certification is often required for electronics deployed in chemical, oil, gas, mining and other manufacturing facilities.

With the higher safety rating, the I/O Server can be installed closer to sensors and actuators to reduce installation costs for monitoring and control of automated machinery. Additionally, the I/O Server has no internal cables and conduction cooling removes heat without open vents or fans for more reliable operation from -40 to 75°C. Metromatics Pty Ltd Contact info and more items like this at wf.net.au/P224

How do you improve reliability and still save money?

UE Solid State Pressure Switches

SHIELDED ETHERNET PATCH CABLES Weidmuller’s Cabinet Line Cat6A shielded ethernet patch cables are suitable for use in industrial and manufacturing environments or where electrical noise is present.

Purposely designed for industry, the cables feature overall screen with foil around each twisted pair and shielded plugs to help combat the excessive electrical noise that is often found in industrial environments.

The cables are low-smoke zero halogen type, in accordance with IEC 60754-2, IEC 60332-1/UL 1581 FT2, and come in various lengths from 0.5 to 25 m for easy use.

They are available in a range of colours for quick and easy identification. Straight cables come in grey, blue, black, yellow, green, red and magenta.

The company has also released 90 and 270° angled cables that are available in grey and suitable for tight bend radius in cabinets.

Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/L962

UPDATED HISTORIAN SOFTWARE The CitectHistorian V4.30 and Vijeo Historian V4.30 are now compatible with the latest Microsoft technology platforms, helping boost overall performance and responsiveness of the system.

With an easy-to-use interface and active data transfers, CitectHistorian and Vijeo Historian can push data from the control systems to the business systems. This means the appropriate levels of plant detail is provided for process evaluation and decision making by senior management.

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

18 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

Key characteristics of V4.30 include: full compatibility with Microsoft Windows 7; full support for Microsoft Windows Server 2003 R2, Microsoft Windows Server 2008 R2 and Microsoft SQL Server 2008 R2 (standard edition); both 32- and 64-bit operating system support; and enhanced reporting functionality with the new Dundas chart controls available in SQL Server 2008 Reporting Services (SSRS).

The Dundas chart controls are able to support new chart types and provide more control over chart axes and formulas. The improved user interface makes it easier to create and work with charts, resulting in enhanced data layout, visualisation and text formatting. The Dundas chart controls also offer Dundas Gauge, which adds dashboard and score carding features to the reports.

Schneider Electric (Australia) Pty Ltd Contact info and more items like this at wf.net.au/L963

www.ProcessOnline.com.au

• Upgrade critical central processing unit (CPU) which takes account of recent technological advances.

• Multi-stream Configuration, multi-station applications metering of gas, wet gas, crude oil, refined products, LPG & NGL’s, etc.

• Extended data logging facilities.

• Increased communication capability, serial and Ethernet.

• Unprecedented support for global measurement standards.

T 1300 553 051 E ausales@ap.emersonprocess.com W EmersonProcess.com/Remote

CORROSION MONITORING BREAKING DOWN THE MISCONCEPTIONS Sridhar Srinivasan, Global Business Leader, Honeywell Corrosion Solutions, USA

The latest technology links corrosion to process conditions more directly and immediately. It also allows corrosion depreciation to be assessed in much shorter time intervals with the ability to control and mitigate the rate of damage and more accurately factor in its true economic impact on plant operations.

20 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

Instrumentation

I

ncreasing productivity and reducing costs is the catchcry we’ve all heard time and time again as companies are forced to turn to new technologies and business practices to meet their objectives.

The process control industry has not been isolated from this activity; however, new productivity and cost reduction ideas have become more difficult to identify as plant and process activity becomes more intricate and complex in order to reduce manpower and expensive overheads. Corrosion control is just one of those areas. With a high potential for productivity improvement or cost containment, managing corrosion within the process control industry has taken a slow but steady move towards new measurement tools that more accurately assess and manage corrosion in a number of different environments. It’s interesting to see that this slow rate of pick-up can most likely be attributed to conventional thinking that: • replacing plant assets severely damaged by corrosion is simply a cost of doing business; • reacting to corrosion problems is the easiest and only known approach within the market.

Many engineers in the chemical process industries (CPI), for example, see corrosion on a ‘straight-line basis’ in terms of repair, maintenance and replacement during fixed-interval turnaround inspections. There is also a generally held misconception that corrosion occurs at a relatively constant rate over time. In reality, a majority of corrosion experiences in these processes actually occurs during short periods when specific process conditions develop.

But how can an engineer know this without the right tools and instrumentation employed to determine this? Here, new technology can assess corrosion deterioration in real time, using the plant control and automation system.

© iStockphoto.com/Olivier Lantzendörffer

The value of corrosion depreciation To many CPI engineers, corrosion is simply a routine part of plant operations and a cost of doing business. A corrosion specialist is called when a problem arises. Once the problem is solved, the plant operates more or less as before, until the next upset occurs. The major impact of corrosion to the business lies in costs associated with lost production, health, safety and environmental issues, and legal liabilities. This is otherwise known as ‘corrosion depreciation’.

The latest technology links corrosion to process conditions more directly and immediately. It also allows corrosion depreciation to be assessed in much shorter time intervals with the ability to control and mitigate the rate of damage and more accurately factor in its true economic impact on plant operations.

New technology allows corrosion monitoring to be assessed via the plant distributed control system (DCS), whereby corrosion measurement is coupled to a suite of key, real-time process variables. This process can lead to gains in many parts of the corporate balance sheet.

What’s new in corrosion monitoring technology?

required to obtain this information. Most importantly, corrosion information can be obtained quickly, sometimes in a matter of minutes, and in a manner consistent with that used for collecting other key process data.

This approach utilises existing data acquisition and automation systems found in production facilities. For example, the plant DCS is used to monitor and control processes, trend key process information, and manage and optimise system productivity. Corrosion monitoring can be integrated into this system, and the data can be automated and viewed with other process variables (PVs).

The advantages of this approach over stand-alone systems include: • Increased cost effectiveness; • Decreased manual labour to achieve key tasks; • A greater degree of integration with in-place systems to record, control and optimise efficient distribution of important information (corrosion and process data, related work instructions and follow-up reports) among different groups required for increased work efficiency and ease of documentation.

Offline measurement Corrosion coupons have underpinned industrial corrosion monitoring for more than 50 years. Coupons must be pre-weighed, distributed to remote locations, installed, retrieved, examined, cleaned and reweighed before the data is processed. Therefore, a good deal of corrosion engineering and related technical staff time is consumed with manual and often routine tasks, as well as with manipulating and viewing historically averaged, offline data. Coupon measurements are offline, labour intensive and not very easily configured.

Online measurement In some cases, corrosion probes used to monitor industrial plants and pipelines are connected to field data loggers that take corrosion rate measurements over a period of weeks or months. This approach is often referred to by corrosion engineers as “online monitoring”, despite the fact the data cannot be accessed, viewed or acted upon in an online, real-time manner. These techniques can retrospectively identify peak corrosion rates and time periods.

The current perception is that there is a high per-point cost associated with conventional corrosion monitoring approaches, largely due to the high cost of a separate infrastructure and the large commitment of time and labour. Additionally, there is a low perceived value because the data is historical and is viewed weeks and months after being obtained. Given this perception, there is a tendency to limit resources for corrosion monitoring because the approach is expensive with only a limited chance of success. It also continues to surprise us that while many plant operators try to squeeze out a 1-2% improvement in efficiency and productivity when they are staring into the face of double-digit cost reduction improvements through corrosion control, particularly if lost production opportunity is included.

Online, real-time measurement

The emergence of online, real-time corrosion monitoring has made it possible to improve the relevance of corrosion measurements.

This approach also reduces the manual effort and the high expense

Feedback from real-time corrosion rate data and adjusted chemical dosage can offer additional gains in efficiency and reduced operating costs, as well as extended run time. Corrosion monitoring has

www.ProcessOnline.com.au

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

Instrumentation

Figure 1: Corrosion monitoring has evolved from off-line to online and online, real-time measurements

developed from a manual, offline process to an online, real-time measurement (Figure 1).

The initial driving force for this migration is the benefit of automation; that is, reduced time and effort to obtain corrosion data with high data reliability. Corrosion monitoring takes on new meaning when it can be viewed at a higher frequency (within minutes) that is consistent with the way process variables are measured. More data leads to increased statistical relevance, quicker response time and a greater ability to understand corrosion in the context of the process being monitored.

The second driver for this migration is the ability to integrate the corrosion data immediately with process data. This is done in an automated manner, within the plant DCS, rather than by the manual methods traditionally available to the corrosion engineer. Some of the usual PVs that are used and measured in CPI control systems include the following: temperature; pressure; flow rate; chemical injection rate; moisture content; valve actuation; level measurement; and analytical data, such as pH, dissolved oxygen and others.

Corrosion transmitters If we take a multivariable corrosion transmitter, for example, the transmitter employs a suite of automated electrochemical techniques that run in the onboard memory of a single transmitter and are used to complement one another. This transmitter produces general corrosion rate data by combining linear polarisation resistance (LPR) measurement and harmonic distortion analysis (HDA) for greater corrosion-rate accuracy, where: • LPR involves the measurement of the resistance to a pulsed voltage between electrodes immersed in the corrosive solution, whereby the resistance calculated is inversely related to general corrosion; • HDA is the technique used in combination with LPR whereby alternating voltages are applied to an arrangement of three electrodes and the primary frequencies and harmonics of the resulting currents are analysed.

The transmitter also provides completely new information obtained on the localised nature of corrosion from electrochemical noise (ECN) measurements. These ECN measurements include small currents and voltages generated at the contact surface between the corrosive solution and the vessel, and provide a good technique for the detection of pitting corrosion.

22 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

When joined in an automated cycle, these techniques can provide two critical, operator-level corrosion PVs at a similar frequency of measurement as expected for current process variables. These operator-level corrosion PVs are: • Corrosion rate: LPR corrosion rate adjusted for a measured B value (see below) determined by HDA; • Pitting factor: Derived from ECN and LPR measurements, providing a three-decade logarithmic scale ranging from general corrosion, through a cautionary zone, to localised pitting corrosion.

Two additional PVs can also be provided through the process control system for specialist observation, diagnostics and intervention: B value: Also called the Stern Geary constant, the B value is derived from HAD, involving the real-time measurement of the anodic and cathodic Tafel slopes. This value is used to adjust the LPR corrosion rates with the electrochemical processes in the system.

Corrosion Mechanism Indicator (CMI): Indicating conditions and trends of passivity in stainless alloys, corrosion inhibition or scale formation.

In addition to these types of real-time measurements, there may be a need to include other online-compatible measurements into the process control and automation system, when they can bring additional value or longer-term corroboration for uses in asset assessment and integrity evaluation.

These corrosion assessment techniques are even more attractive if they can be easily automated and coupled with the modern communication methods such as wireless technologies. Techniques include electrical resistance corrosion measurements, ultrasonic thickness, pulsed eddy current and fibre-optic strain measurement, as well as other ancillary techniques that may become available as these complementary technologies develop.

Benefits Through the integration of corrosion with modern, industrial process control technologies, an array of substantial operational and costsaving opportunities become available. Discussions with refinery operations and corrosion personnel also show the key benefits when deploying these new technologies: • Increased ability to process crudes with higher margins - leading to large savings and increased profits.

• Reduced cost of unscheduled shutdowns.

www.ProcessOnline.com.au

Instrumentation

IF WE TAKE A MULTIVARIABLE CORROSION TRANSMITTER, FOR EXAMPLE, THE TRANSMITTER EMPLOYS A SUITE OF AUTOMATED ELECTROCHEMICAL TECHNIQUES THAT RUN IN THE ONBOARD MEMORY OF A SINGLE TRANSMITTER AND ARE USED TO COMPLEMENT ONE ANOTHER.

• Improved asset reliability resulting in improved run length - up to 10% reduction in maintenance costs.

• Improved unit operation as a result of better corrosion monitoring that may result in a 2% increase in throughput, or potentially the ability to process more of a lower quality feed.

• Reduced health, safety and environmental exposure resulting from fewer unscheduled emissions to the environment - 3% savings.

• Improved safety record as a result of fewer shutdowns - 5% reduction in cost.

• Savings due to optimised chemical cost resulting from better monitoring - 10% reduction.

• Increased operator effectiveness by bringing the corrosion data online and in the control room. This leads to improved decision making with new insights and improved issue resolution time.

influencing factors that can vary with time and cause dynamic corrosion events. The long intervals associated with inspections and offline measurements do not give the operator the opportunity to correlate corrosion daytrips with operating and process parameters, ultimately making control a difficult proposition.

To make gains in productivity, corrosion control must become part of everyone’s job function in a similar manner to quality control or safety, and the corrosion specialist can provide key real-time input to significant corrosion situations as they occur.

By implementing an appropriate and correspondingly dynamic means of corrosion appraisal, chemical manufacturers can better manage industrial processes and related corrosion prevention treatments, minimise corrosion upsets and failures, and maximise the availability of the plant assets.

Conclusion

Honeywell Limited

Corrosion behaviour in process environments has a number of

Contact info and more items like this at wf.net.au/P321

Meet all your needs with one cost-effective controller.

When you need a flexible, scaleable, integrated control and motion solution Logix is the answer. From simple to complex machinery CompactLogix™ is Integrated Architecture in its simplest form helping reduce the volume of hardware Experience your future today, visit www.RockwellAutomation.com/ think/yourfuture

www.ProcessOnline.com.au

you need, making it quicker for you to meet your customers’ requirements. www.RockwellAutomation.com.au www.RockwellAutomation.co.nz

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

NEW PRODUCTS

COMPRESSOR SILENCER HOOD Boge has recently enhanced its small C series range of screw compressors up to 15 kW. The compact C 10 LDR to C 20 LDR are now available with Boge’s super silencer hood, making this range suitable for point-of-use applications.

The Boge C series screw compressors are already very quiet in operation, emitting very low sound pressure levels. However, where an even quieter operation is required, such as at point-of-use, Boge has introduced a sound insulation hood as an optional extra. This hood encloses the screw compressor, creating a virtually silent operation at just 61 dB(A).

The Boge C 10 LDR to C 20 LDR, directly coupled screw compressors are mounted on a horizontal compressed air receiver with a refrigerant dryer, providing a complete compressed air centre.

The directly coupled C series models up to 15 kW are efficient and quiet in operation requiring only a minimum footprint. Available in the standard pressure of 8 and 10 bar, output capacities range from 1.060 to 2.280 m³/min and motor power from 7.5 to 15 kW.

CUSTOM-BUILT VALVE AUTOMATION CONTROLS Rotork Fluid Systems supplies a range of custombuilt, locally engineered and manufactured pneumatic and hydraulic control panels. The range provides control panel solutions for arduous applications in hazardous areas and corrosive environments.

The company specialises in stainless steel control components, fittings and tube. The valve actuator control panels are fabricated and tested in Bayswater, Victoria, and services include liaison with customers to develop an approved engineered solution; schematic layout diagrams and general arrangement CAD drawings for customer approval prior to manufacture; final ‘as-built’ general arrangement drawings; individual testing for every control panel; third-party inspection and testing, as required; and compliance certification to meet SIL and hazardous area requirements, including IEC Ex. Rotork control panels are supplied for new

Boge Compressors Ltd

installations on complete actuator systems, and

Contact info and more items like this at wf.net.au/L699

retrofit solutions to all makes and models of installed actuators.

The company’ Site Service team offers on-site inspection and audit of the customer’s require-

PRESSURE TRANSMITTER FOR OEMS

ments to determine the best solution. This often involves space restrictions, upgrading hazardous

WIKA has designed its O-10 pressure transmitter for indus-

area equipment to latest standards and general

trial applications anywhere in the world, and it is suitable

improvements in the materials and workmanship of

for customers with high volume requirements.

installed equipment. The team also offers complete

The O-10 works with a measuring range of from 0-6 bar to

on-site installation, commissioning and training

0-600 bar. A wide choice of pressure connections, electrical con-

to ensure satisfactory handover and trouble free

nections (including DIN-A) and output signals is also available.

start-up. Extended warranty is available where the

With the O-10 pressure transmitter WIKA is aiming mainly

team is engaged in installation and commission-

at manufacturers of pumps, compressors and hydraulic

ing activities.

systems who have an annual requirement of more than

Rotork also provide logic panels, high-pressure

1000 instruments of identical specification. The minimum delivery

gas reduction panels and other related systems

quantity is 50 pieces.

If required, the O-10 can be ordered with the customer’s own company logo and model designation.

WIKA Australia

that control the flow of air, liquids or gases.

Rotork Australia Contact info and more items like this at wf.net.au/P194

Contact info and more items like this at wf.net.au/L710

24 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

NEW PRODUCTS

ENCODERS WITH SSI INTERFACE Updated versions of the Posital Optocode encoders with SSI interfaces have been released, which now include support for additional output drivers for incremental signals (RS422/TTL and push-pull/HTL), resolutions of 1024, 2048, 4096, 8192 or 16384 PPR per output, a reference impulse and an extended voltage range covering 4.5 to 30 VDC. Additional diagnostic functions can be implemented via an alarm bit for self-diagnosis of the Opto-ASIC and hardware/software monitoring. They are suitable for use in wind power applications, where both rotor speed and the absolute position of the rotor must be determined.

The encoders retain features of previous models, such as the integrated preset function that allows users to assign a preset value to the current position of the shaft. A version with a hardware preset push-button featuring two integrated LEDs for easy status and error diagnosis is optionally available.

The synchronous serial interface enables the operation of up to 10 encoders on one data line. They are based on a single-turn sensor with an integrated Opto-ASIC which provides a resolution of 16 bits per revolution.

Additionally, a maximum of 16,384 revolutions (14-bit) can be registered in multiturn mode. Available as solid, hollow and hub shaft versions, the units can be fitted with a connector or a cable exit. They provide a maximum transfer rate of 2 MHz and

ensure

cycle times below 25 µs. The housings of the encoders provide IP65 protection (IP64 on the shaft side, up to IP66 with an

COMPONENTS optional shaft seal).

Plant Control & Automation

Contact info and more items like this at wf.net.au/L570 CONTROL COMPONENTS

Control Components Control Components

Hygienic solutions?

Flow, Level & Pressure

CONTROL COMPONENTS Control Components

Switch to Sitron

FISCO APPROVED FIELDBUS SYSTEM The MooreHawke Route-Master fieldbus system has a new ATEX approval (FM pending) as a redundant intrinsically safe fieldbus system permitting the connection of any mix of FISCO and Entity devices.

Process Sensors for Food & Beverage

A Route-Master system consists of up to eight trunk isolator modules in a 19-inch rack, each connected to one or more RM100 fieldbus device couplers. This combination is now approved suitable for any mix of FISCO and Entity field devices. The RM100 rack incorporates hot-swappable and load-sharing redundant DC power cards and full galvanic isolation. Intrinsically safe approvals extend to IEC Gas Group

Sitron Flow, level & PreSSure SenSorS • Sanitary Designs • No moving parts – longer life • AC, DC and Universal powered models • Relay or Analogue output available • Tri-Clamp, threaded & flanged connections

02 9542 8977

The duplex FISCO Route-Master gives a calculated MTBF of 468 years, and also allows the full FOUNDATION Fieldbus network length of 1900 m with 120 m spurs.

RM100 device couplers have auto-resetting short-circuit protection, automatic segment termination to eliminate common installation errors and commissioning delays, and LED status indicators. MooreHawke’s short-circuit protection method prevents segment failure caused by multiple device faults. A ‘fold-back’ technique automatically removes fault loads from the segment and does not permit any current flow to those devices until faults are corrected. Manual termination is also

TAKE CONTROL

CCEZY.COM.AU

IIC (NEC Groups A and B), with up to 350 m per segment.

33 years of experience in Food & Beverage

26 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

offered at the user’s request.

Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/L794

www.ProcessOnline.com.au

9 ÕÊ> Ài>`ÞÊ ÛiÊÌ iÃiÊ ÊÊÊÊÊÊÊÊ«À `ÕVÌÃÊvÀ Ê >> iÌ°°°

ÝV Ì }Ê iÜÊLÀ> `ÃÊÜ Ê >Õ V ÊÃ t ÕÌ À Ãi`Ê ÕÃÌÀ> > Ê` ÃÌÀ LÕÌ ÀÊv À

i L ÕÀ iÊUÊ ««Ã > `ÊUÊ i ` } ÊUÊ- i««>ÀÌ ÊUÊ `ÕÀ>ÊUÊ LÕÀÞÊUÊ7 } }ÊUÊ-Þ` iÞÊUÊ >Ì ÕÀÃÌÊUÊ À ÃL> iÊUÊ >`ÃÌ iÊUÊ/ Ü ÃÛ iÊUÊ >ÀÜ ÊUÊ Õ LÕÀÞÊUÊ Vi ÌÊUÊ `i > `iÊUÊ >Õ ViÃÌ ÊUÊ ÕV > `Ê <

> Ê£ÎääÊ /Ê­£ÎääÊÎÓÓÊÈÎn®Ê v ÀÊÞ ÕÀÊ V> Ê >> iÌÊ i LiÀ° `>> iÌ°V °>Õ

POWER SUPPLIES The

dip-coated

Quint Power power supply units have an adjustable output voltage from 18 to 29.5 VDC, output currents of 5, 10, and 20 A and are capable of tolerating 100% humidity.

Input voltages from 85-264 VAC or 90-350 VDC supply the three single-phase devices. The three-phase module with 20 A nominal output current can be operated on networks with 3x 320-575 VAC or 450-800 VDC. Offering an efficiency of up to 93%, the devices generate minimal heat loss, thus not only saving energy but also extending the service life of the components. The wide temperature range of -25 to +70°C makes the unit suitable for use in a variety of applications.

In addition to the usual industrial approvals, the dip-coated modules with nominal currents of 5 A and 10 A conform to EN 60079-15 (ATEX directive). They can be installed in a potentially explosive area in which Category 3G equipment is required (II 3 G Ex nA nC IIC T4 Gc). The modules are also IECEx certified (Ex nA nC IIC T4 Gc). All Quint Power devices comply with UL standard ANSI/ISA 12.12.01 as well as the specifications for Class I, Division 2, Groups A, B, C, and D (Hazardous Locations).

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/L788

COMPRESSOR PROTECTION FOR HARSH ENVIRONMENTS In harsh mine site and construction environments, most variable-speed compressors available in the Australian marketplace may struggle with high heat, humidity and dust levels. The result can be frequent breakdowns or shutdowns, costly component failures or expensive preventative maintenance.

CAPS Australia has released its Harsh Environment Efficient VFD Option (HEEVO) to suit Ingersoll Rand compressors from 11 to 350 kW. The HEEVO is suitable for mining, timber and other rugged industries where high dust loads are common. The option is also appropriate for applications operating in offshore, marine and similar environments where humidity is the main concern.

The sensitive nature of variable speed drive compressors means that normally they are more at home in a clean plant room than in a harsh environment where reliability is the top priority. Achieving reliability normally means compromising on efficiency.

The HEEVO enhances the overall IP rating of the compressorâ&#x20AC;&#x2122;s motor and electrical components so that there is protection against entry of dust that is in sufficient quantity to interfere with satisfactory operation of equipment, and protection against extreme humidity, heavy seas and jets of water from all practical directions.

CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/L623

28 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

NEW

270x88mm HACH PACIFIC_WWF

9/6/11

9:31 AM

Page 1

PRODUCTS

ETHERNET SWITCH Belden has extended its Hirschmann product range with a 9-port version of its Octopus OS20 switch series, providing Fast Ethernet ports (10/100base-Tx) with vibration-resistant M12 connections in D-coding.

Further features include a robust IP67-rated metal housing and an extended temperature range from -40 to +70째C. The Octopus also meets EMC and fire protection requirements for use in rail vehicles. As the switch can be cascaded in any way, decentrally structured automation networks with short transmission paths can be implemented with the respective terminal devices.

The Hirschmann basic software is installed on this layer-2 switch, supporting both various management

Products. Support. Expertise.

When you buy direct from Hach Pacific you will receive access to the largest offering of the highest quality lab and process water analytics as well as outstanding service and application support. Hach is your trusted partner in water analysis.

and security functions and fast redundancy methods such as HIPER-Ring, MRP and RSTP.

Innovative Process Instrumentation

Integrated Lab Solutions and Chemistries

Expert Support

Dependable Service

The switch is designed for wall mounting, and can be quickly put into operation. Configuration is possible either via a command line interface (CLI), DHCP relay agent option 82, HiDiscovery or the ACA11-M12 EEC auto-configuration adapter.

RMON, port mirroring and LLDP (Topology Discovery 802.1ab) are provided for diagnostics.

Contact a Hach Pacific office near you for direct order and sales support: AUS: 1300 887 735 NZ: 0800 50 55 66 www.hachpacific.com

A floating signal contact signals alarms independently of the data network. The switch also has LEDs on the front that display both the device and network status, and the data transfer and power supply.

Information can be retrieved via a serial V.24 interface or the ethernet ports. The switch is monitored and configured via SNMP, a standard web browser or the Hirschmann Industrial HiVision network management software.

Belden Australia Pty Ltd Contact info and more items like this at wf.net.au/L558

www.ProcessOnline.com.au

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

Coca-Cola Hellenic reduces energy consumption by 75% Reducing energy consumption is one of the most important requirements today when modernising machines and systems. Often, there is great potential for saving energy - which, in the end, means saving money.

Coca-Cola Hellenic Austria is the licensed bottler of the Coca-Cola Company in Austria.

When the company decided to modernise a transport line in its bottling plant in Vienna, reducing power consumption and reducing CO 2 emissions were the main priorities. Additional requirements included standardising the drive variants that are used in order to simplify the stocking of spare parts and facilitating a fast restart of the system after the conversion. The final goal of the retrofit was to simplify maintenance.

SEW-Eurodrive GmbH and Coca-Cola Hellenic Austria have long shared a close partnership. And this isn’t just due to the fact that the companies are located near one another in Vienna. The companies have long engaged in regular business contact regarding standard gearmotors and frequency inverters. It was because of this that the SEW Vienna employees were able to recognise the numerous benefits that the mechatronic drive system would have to offer the client, Coca-Cola Hellenic. With detailed energy consumption calculations, SEW-Eurodrive was able to show that the transport system could attain the highest level of energy efficiency using Movigear.

In less than six months, the leaders of the beverage company managed to organise the changeover of their beverage line - from filing the budget and taking care of the technical planning, all the way to fully utilising the narrow time window for the conversion. By the beginning of 2010, it was time: the company was ready to modernise transport line 2a. This line links the bottling plant for Coca-Cola, Fanta and Sprite to the palletising system via the packaging machine. PET bottles holding

0.5 to 2.5 L are handled in this area.

Previously, the line was driven by standard line-powered gearmotors. As part of the modernisation, the company replaced a total of 39 gearmotors - some with inverters, but most without - as well as the controller for the drives.

Instead of using 24 V switch contactor technology for line-powered motors, the company opted for Profibus interfaces. This allows the operator to change the speed as required and adjust it precisely to suit the process. In addition, the Profibus interface optimises the system’s ability to shut down the line in case of a jam and minimises idle times. These measures result in a noticeable reduction in power consumption.

The Profibus transmits the control signals from the PLC to the drive and transmits current diagnostic and status signals from the drive to the controller. The use of Profibus also offers completely new diagnostic options. The operator now has much more than an I/O display: the speed and current are displayed on a keypad, allowing the operator to check whether mechanical components are moving freely, and, should service be required, the fault type is displayed. Bus operation also allows the operator to record the current for general monitoring purposes and serves as an indicator of capacity utilisation.

With the Movigear system solution, power supply and communication are handled using SNI technology (Single Line Network Installation). This allows energy and communication transfer in one shielded cable, thereby decreasing the number of components required while significantly reducing the installation cost. The actual mechanical conversion of the system took place over an extended weekend, from Friday morning to Sunday evening. In this short period of time, the old drives were disconnected and mechanically removed and the new drives were mechanically mounted, electrically installed and started up. On Monday morning, production started up again in the bottling plant.

With the complete system solution, CocaCola Hellenic Austria was able to reduce the power consumption of the transport line by a sensational 75% (in comparison with the technology previously in use). This means that the investment pays for itself in less than one year. Extrapolated from a fiveday measurement of the amount of energy consumed, the new system will generate an estimated savings of 41 tons of CO2 annually.

30 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

These savings were achieved by multiple measures carried out in parallel; however, SEW drive technology played a major role in these results.

Erwin Langela, Manufacturing Director of Coca-Cola Hellenic Austria, explains, “For Coca-Cola Hellenic, it was always an important priority to optimise production, not only economically, but also ecologically. For this reason, we were searching for different ways to reduce our CO 2 footprint, which serves as a measurement of the effect of our daily activities on the environment and climate change. SEW-Eurodrive suggested replacing the drives in our conveyor belts with the Movigear mechatronic drive system.

Now, half a year later, independent audits show we were able to reduce our power consumption by 75%. That translates to an annual reduction of 41 tons of CO2. We want to keep going in this direction. Not only do we want to implement the Movigear system in Vienna - we plan to use it in Edelstal (Austria) as well, and we want to use SEW technology in the bottling of our Römerquelle mineral water.”

Thanks to these amazing results, upon the start of the new application, SEWEurodrive received another contract for a second transport line for PET bottles with soft drinks. As part of the modernisation of this line, the first step is to take stock of the existing system by generating a parts list: how many drives are currently in use, what the gear ratios of these systems are, etc.

Coca-Coca Hel lenic Austria is so confident about SEW drive technology that the company now specifies Movigear as the drive system in its calls for bids to system designers.

SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/P313

www.ProcessOnline.com.au

DISTRIBUTED I/O SYSTEM Turck has released the 4AI4AO-VI analog I/O module, which is compatible with

NEW PRODUCTS

two of the company’s BL distributed I/O products: BL67 and BL Compact system. Featuring four analog inputs for current or voltage and four analog outputs for voltage, the module provides both control and feedback in one package.

The 4AI4AO-VI is designed for use with Turck’s BL67 modular I/O system and BL Compact system. BL67 combines all of the flexibility of an in-the-cabinet I/O system with modularity, ruggedness and connectorisation, while the BL Compact system is an on-the-machine solution that obtains and transmits signals via diverse fieldbus protocols, without requiring a protective enclosure. Supporting both M8 and M12 I/O connectors and offering compatibility with a variety of communication protocols, such as EtherNet/IP, DeviceNet, CANopen and Modbus TCP, the BL family provides a high degree of I/O versatility for a wide range of applications.

For enhanced application compatibility, the 4AI4AO-VI is ruggedly constructed to withstand diverse environmental challenges. Operating in temperatures ranging from -40 to 70°C, rated to IP67 and UL listed, the module provides optimal performance in applications that yield extreme temperatures, moisture, shock or vibration.

Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/P312

WIRELESS AP/ BRIDGE The Moxa AWK-3121 is a 3-in-1 industrial wireless AP/bridge/client that is suitable for applications such as power automation, transportation automation, and oil and gas applications. It supports multiple IEEE 802.11 standards and higher security levels, including wireless communication in the 5 GHz band.

The Moxa AWK-3121 is also WPA2-enabled and highly secure for wireless networks that use Advanced Encryption Standard (AES) technology. Features include redundant DC power inputs, Powerover-Ethernet, RS232 console management support, two digital inputs and one relay output, and a wide temperature range from -40 to 75°C. The AWK-3121 provides higher security levels of authentication and authorisation for increased safety.

Security features include 802.11x/ RADIUS, AES, TKIP support, and disabling of SSID broadcasts, as well as IP packet filters to prevent hacker attacks.

The AWK-3121 also supports STP/RSTP (IEEE802.1d/w) allowing the AWK-3121 to prevent network looping and to increase system availability by setting a redundant path.

Madison Technologies Contact info and more items like this at wf.net.au/P225

www.ProcessOnline.com.au

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

BACKGROUND SUPPRESSION PHOTOELECTRIC SENSORS 10 KEY STEPS IN SELECTING AND USING THEM Jeff Allison, Pepperl+Fuchs Inc

Over the past decade, photoelectric sensing has undergone a steady transition in which older, conventional sensors are being replaced by an innovative technology called background suppression (BGS).

B

GS is a more efficient method of sensing that doesn’t rely on how much light is reflected to the sensor’s light-sensitive receiver, but rather on where the light is reflected on the receiver.

This endows BGS with certain unique sensing capabilities.

The most obvious is its ability to disregard machine panels, belt conveyors or other materials behind what is to be sensed. It also consistently senses objects regardless of colour or reflectivity, so glossy Mylar is detected similarly to brown corrugated cardboard or even black matte painted surfaces. BGS can precisely detect leading edges and small items, such as springs or screws. BGS sensors also simplify sensing by removing the cost and clutter of reflectors and two-housing, through-beam arrangements.

Selecting and setting up the best BGS sensor for an applica-

tion doesn’t have to be difficult if the following ten key points are kept in mind.

32 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

1. Infrared has better performance than visible red.

When selecting a BGS sensor, an infrared (IR) light source always produces superior sensing performance over a sensor with a visible red light source. Sensors with IR emitters have higher power and lower colour sensitivity than their visible red counterparts. This means they can be used at greater sensing distances and can sense different objects more consistently. IR emitters are more efficient and can be driven with higher current pulses compared to visible red versions. The best sensing performance in background suppression is accomplished with fixed-range, short-distance sensors with IR emitters.

Sensors

2. A fixed background is better than no background.

BGS sensors are designed to compare two signals: light reflected from near objects (such as the material being sensed) and light reflected from far objects (namely, the background).

When a defined signal from a fixed background is present, it minimises the effect of disturbances in the application, such as dust particles collecting on the sensor’s lens in a dirty environment. The reflected signal from the background is easier to see and compare (as opposed to no reflected signal) if there is no background object present.

3. No background is best for detecting small objects.

Equally important, a BGS sensor should always be selected so its light spot is smaller than the objects it will detect. This is for good reason: if the sensor’s light spot isn’t completely covered by the object, then the object reflects some of the sensor’s light, but a background material can reflect the remainder of it.

And because the sensor determines object presence based on a comparison of reflected light from the near field and far field, it is possible for a small object to not be seen if the sensor’s light spot does not cover enough of the object.

BGS sensors are available with laser light spots or fine focal points to detect items that are as small as just a few millimetres.

© iStockphoto.com/Terry Wilson

4. Tilting the sensor at a slight angle is best to sense shiny objects.

In Figure 1, the left chart shows the adjusted detection distance compared to the actual sensing distance for white, grey, and black objects using a BGS sensor with a visible red light source. At an adjusted distance of 700 mm, the measured sensing distance varies by approximately 150 mm depending on what colour is present. The right chart shows the same for a BGS sensor with an infrared source. This results in a sensing distance variation by colour that can be just one third that of visible red versions, at the same distance.

In fact, the only advantage to using a visible red emitter is when a visible light spot is needed to align the object to be detected. Alignment can be more desirable than sensing performance in some applications, especially if the item to be sensed is small or is sensed through an aperture.

www.ProcessOnline.com.au

Especially when sensing a highly reflective material such as glossy packaging or a Mylar web, it is best to position the BGS sensor so its optical axis is approximately 5 degrees off perpendicular to the detection plane. In Figure 2, scenario (a) shows that a very reflective object can result in glaring or blinding, in which the reflected light beam floods the receiver and covers both receiver elements. But mounting the sensor with the slight angle as shown in scenario (b) of Figure 2 reduces the glaring reflection considerably, so the object can be detected.

5. Adjust or mount a BGS sensor from the background, not the object.

After a BGS sensor has been selected and is installed in the application, it may be necessary to adjust its sensitivity so that the object to be sensed is in the detection field and the background is beyond the maximum sensing distance. This is normally accomplished using a potentiometer on the sensor housing. Turning it clockwise effectively increases the distance from the sensor where it detects objects, while turning it counterclockwise decreases this distance.

A common mistake is to place an object to be detected in front of the sensor and adjust the sensitivity just to the point where

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

Sensors

Figure 1: Effect of object colour on sensing distance.

Figure 2: Effect of tilting the sensor for shiny objects (image not to scale).

that object is sensed. But because there is a slight difference in sensing distances based on colour (as shown in Figure 1), it is possible that a darker object might not be detected.

Instead, it is best to adjust the sensitivity to the background, rather than to the object. This allows the greatest range of object colours to be repeatedly detected. That means turning the potentiometer until the background is sensed, then turning it slightly in the opposite direction until the background is not sensed.

For tamperproof models with no adjustment, the potentiometer is replaced by physically positioning the sensor relative to the object.

6. Movement direction can be a factor in how BGS detects.

Although a less common occurrence, the direction an object travels through the sensing field of a BGS sensor can determine if it is detected. Three simultaneous conditions could result in a brief moment where the object is not sensed. In this scenario, the object must move in the plane directly at the sensing threshold, have a high-contrast pattern (such as black-white), and move parallel to the emitter-to-receiver axis. With these conditions, a BGS sensor may not detect the object. This is because the sensor’s light spot straddles the high contrast such that the dark portion reflects less to the near element receiver

34 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

Figure 3: If a high-contrast object, such as the white-black cylinder in this image, is to be detected at the sensing threshold, the sensor should be positioned in a specific way. a) It should not move parallel to the axis on which the emitter and receiver lenses are located. b) It should move in another axis, either toward or away from the sensor or perpendicular to the emitter and receiver axis.

compared to what the light portion reflects to the far element receiver. Turning the sensor or object by 90 degrees or moving the object closer to the sensor remedies this situation. This is known as the Pepita effect.

7. BGS sensors optically ‘burn through’ many transparent media.

By design, a BGS sensor has a small light spot size compared to conventional sensors. The smaller the light spot, the more likely it is to pass through - rather than be reflected from - a clear or transparent object like shrink wrap. This can be called optical ‘burn through’. As such, BGS sensing is not optimised to always detect transparent objects. Instead, a wide-beam diffuse or a retroreflective sensor specifically designed for clear object detection are the best methods of sensing transparent films, wraps, glass and other objects.

On the other hand, BGS sensors can often be used when mounted directly against a clear Plexiglas or glass shield to detect an object on the other side.

8. BGS sensors are not contrast sensors.

BGS sensors are, by design, not for contrast sensing. A contrast sensor is a different type of sensor that is used to detect differences in colours, such as when sensing registration marks on

www.ProcessOnline.com.au

Sensors

BGS CAN PRECISELY DETECT LEADING EDGES AND SMALL ITEMS, SUCH AS SPRINGS OR SCREWS. BGS SENSORS ALSO SIMPLIFY SENSING BY REMOVING THE COST AND CLUTTER OF REFLECTORS AND TWOHOUSING, THROUGH-BEAM ARRANGEMENTS.

a web to trigger a cut. In fact, BGS sensors are closer to the polar opposite of contrast sensors, as the former are intentionally designed to detect variously coloured objects, from totes to papers to circuit boards, at a similar distance.

9. Hysteresis < black-white difference < maximum sensing distance.

A helpful rule of thumb for BGS sensors is the relationship between some of their specifications. Hysteresis is the difference between the distance at which an approaching object is seen and the distance at which a retreating object is no longer seen. Hysteresis is typically very tight for BGS sensors. The black-white difference is the disparity between the maximum distance at which a black test object is sensed and the distance at which a white test object is sensed. It is a good indication of the sensorâ&#x20AC;&#x2122;s sensitivity to colours. And the maximum sensing

www.ProcessOnline.com.au

distance is the distance beyond which no objects are detected.

Hysteresis is typically smaller than black-white difference, and both are smaller than the maximum sensing distance.

10. Be aware of not only maximum sensing distance but also minimum.

While the maximum distance at which a BGS sensor can see an item is certainly important, it can be easy to overlook the minimum sensing distance specification. Generally, the minimum sensing distance, also called blind range, is only a few millimetres to a few centimetres. For applications that require sensing up to the sensorâ&#x20AC;&#x2122;s face, a related technology, background evaluation, may be a better alternative.

Pepperl+Fuchs (Aust) Pty Ltd Contact info and more items like this at wf.net.au/P237

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

FLOWMETER The Influx FloTrak metal VA flowmeter is designed for the measurement of gas and liquid. Fluid passing through an orifice within the tube causes a profiled float to assume a position where the forces created by flow are balanced by the weight of the float. A magnet in the float is sensed by the FloTrak system, providing a direct reading flow rate scale, optional alarms or a 4-20 mA output.

The flowmeter is installed in a vertical line with flow upwards and is normally supported by the surrounding pipework. Several styles of instrument are available. As a direct reading indicator it provides clear indication over a 100 mm long scale, and can be scaled to suit exact process conditions. As a flow alarm unit, the direct reading indicator also provides one or two fully adjustable setpoint trips, for connection via an interface unit. As a flow transmitter, it provides a 4-20 mA loop output proportional to percentage of reading.

The flowmeter has simple construction and is rugged and easily installed.

It is claimed to have a stable zero point unaffected by installation and low hysteresis. Gas damping is fitted as a standard on gas ranges, and alternative flange connection ratings and types are available on request, as well as special calibrations or flow ranges. Approvals include EEx ia IIC T6 and EEx nA T6.

Duff & Macintosh Contact info and more items like this at wf.net.au/L432

TEMPERATURE TRANSMITTERS The Yamatake advanced temperature transmitters, models ATT60 and ATT70, are field instruments that convert inputs from thermocouples, mVs and resistance thermo-bulbs into analog (4-20 mA) and digital signals and transmit them to receivers. Various parameters can be remotely set, and self-diagnosis can be performed through the Smart Field Communicator (SFC). They can also execute two-way communications between the SFC, or HART 375 communicator, and, via DE protocol, with the TDCS3000 or 3000X and a database, thus facilitating self-diagnosis, range resetting and automatic zero adjustment. Settings, adjustments and self-diagnosis can be done easily by SFC or HART communicator.

The following models are available: the Advanced Temperature Transmitter with FOUNDATION Fieldbus Model ATT60; the Smart Temperature Transmitters (Integral Sensor Type) Model ATT61/71; Temperature Sensor Model ATT90; and Metallic Protecting Well for Temperature Sensor Model ATT9X. ThermoPLUS handles all thermal sensors, and any temperature range can be set as required within the one transmitter, thus giving the optimum range for a given process. The transmitters are available with a range of flexible sensor types, thus reducing engineering work costs.

The two-wire system of the models ATT60/70 requires no compensation wires or field cables, and the system has a self-diagnostics function. They can also work with abnormal ambient temperatures of -40 to 85째C. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/L015

36 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

NEW PRODUCTS

ETHERNET SWITCHES/ ROUTERS The RADiFlow 3080, 3300 and 3700 switches/routers from RAD Data Communications offer enhanced security, with an integrated, service-aware firewall per

EXTENDED DRIVE RANGE Rockwell Automation has extended the power range of its Allen-Bradley PowerFlex 755 AC drives to 900 kW and added 690 V ratings. The new drives are suitable for a variety of heavy industrial applications and provide users with increased application flexibility, advanced diagnostics and a common DC bus option.

The common DC bus option allows users to connect the AC drive to a common DC bus configuration, which takes advantage of different drive cycles to share energy. In this configuration, a DC bus acts as a common energy source that feeds energy from a generating load to a motoring load. Managing energy from a shared source increases overall system performance and reduces losses - ultimately improving the application’s energy efficiency.

This latest frame size includes an embedded ethernet port and five option slots, so users can tailor it to their application. Option modules include I/O, feedback, safety, additional communications and an auxiliary power supply.

A convenient rollout design allows easy access to the drive for fast installation and maintenance. The drive’s converter and control pod can remain in the unit while the inverter is rolled out, so control wiring can remain connected.

In addition to the extended power range, a firmware upgrade for all PowerFlex 755 drives will include interior permanent magnet motor control and a ‘stop dwell’ feature to help prevent a motor from coasting to a stop.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/P170

port, and can handle temperatures from -40 to 75°C without fans.

The integrated firewall on each port of the RADiFlow switches provides a network-based distributed security solution equivalent to the use of personal firewalls on all the systems. The firewall is ‘application aware’ in that it inspects the contents of the data packets according to the rules of the industrial protocol used. It operates on user-defined access rules for each end device up to the level of the industrial protocol command. In addition, the switches provide an integrated set of security tools so that a complete, in-depth defensive solution can be readily deployed.

The enhanced security features of the RADiFlow are of particular value in nationwide infrastructure applications that have a wide geographic distribution of small unmanned facilities since, in such situations, an attacker that successfully gains access to a single remote location can maliciously manipulate the behaviour of all the devices in the network.

Other features of the RADiFlow switches/routers include: up to 28 GB ethernet throughput; RS232/RS485 interfaces; redundant power supply; network resiliency using MSTP/RSTP, or G.8032 rings; 802.3ad link aggregation; IP routing supporting OSPF; multicast routing using IGMP snooping; secure IPSEC VPN tunnels and industrial protocol gateway capability.

NSC Group Pty Ltd Contact info and more items like this at wf.net.au/L441

www.ProcessOnline.com.au

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

NEW PRODUCTS

MULTIPLE-PORT FIREWALLS Through Belden, Hirschmann is introducing the Eagle20-0400 and Eagle30-0402 multiple-port firewalls which claim to deliver significant cost savings while achieving greater link speeds.

They are claimed to be the first firewalls on the market in a convection-cooled DIN rail housing that supports six LAN ports and WAN connectivity.

This extended number of ports enables users to deploy a single device instead of having to use multiple Eagle20s.

Because Belden has focused on the needs of industrial networks, the

10 GB ETHERNET SWITCH The CP6930-RM is a 10 gigabit ethernet rackmount switch supporting up to 32 ports. It is hardened to meet high shock and vibration, EMI and extended temperature ranges. Multiple configuration options provide SFP+, SFP, RJ45 and M12 connectors.

Based on the Kontron 10 gigabit ethernet CompactPCI Switch CP6930, the Kontron CP6930-RM provides a ready-to-run rackmounted unit including redundant AC or DC power options. The non-blocking, fully managed L2/L3 10 gigabit ethernet switch provides up to six ports 10 GbE and up to 26 ports 1 GbE. Up to six 10GbE ports are directly accessible on the front via SFP+, plus two 1 GbE ports over SFP. A second variant, the CP6930-RM-24, is preconfigured with front interface modules for an additional twelve 1 GbE ports over RJ45. On request, M12 connectors are available for extremely demanding environments.

Eagle20-0400 and Eagle30-040 bring a number of key benefits over current options by offering multiple ports, gigabit ports and WAN connections. They also have a greater temperature range, more flexible deployment possibilities and offer wider voltage ranges.

The Hirschmann Eagle20-0400 firewall supports four 100 Mbps ports, while the Eagle30-0402 firewall supports four 100 Mbps ports and two 1 Gbps SFP ports. Initially, the hardware release will support ethernet ports only. A later hardware release will also support WAN connections, including ADSL, SHDSL, VDSL, E1/T1 and UMTS. The LAN and WAN boards have been designed in-house to support industrial specifications. This enables the product to support non-standard voltages such as 72 VDC. The devices are delivered ‘modular from the factory’, so they can be delivered with the required combination of LAN and WAN ports.

The CP6930-RM switch provides features such as IP forwarding, L2 and L3 multicast, quality of service and VLANs. The feature set has been extended to facilitate common management and configuration tasks in embedded and rugged environments, including reliable software updates in the field, replication of configurations over multiple

Belden Australia Pty Ltd

devices, dual boot images with roll-back capabilities

Contact info and more items like this at wf.net.au/P310

and write protection of internal memory.

Kontron Australia Pty Ltd Contact info and more items like this at wf.net.au/L960

FREE SUBSCRIPTION! What’s New in Process Technology is FREE to qualified ICT

industry professionals in Australia & New Zealand.

To continue receiving your free copy you will be asked to register every three years.

Quick registration @ www.ProcessOnline.com.au/subscribe 38 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

NEW White Papers

now available online!

Are water operators as safe as they could be?

During the September 2011 Water Industry Operators Association meeting in Victoria, Hydro Innovations conducted a survey of operators and other water industry professionals as part of the official competition program. This paper summarises the findings of the survey and details explanations for them.

DAQ SOFTWARE DEVELOPMENT TOOL The DAQ Navi application for configuring PCI, USB and PCI-104 data acquisition devices has been released. The DAQ Navi application includes the Software Development Kit, Device Driver and Device Test Utility with User Guide to replace the previous multiple drivers, device manager and SDK. DAQ Navi allows users to configure and run basic parameters through Visual Studio.net, or users can use class libraries to write their own device functions using C/C++, C#, VB.Net or Delphi, therefore providing a more robust method of controlling devices. An improved device driver allows the DAQ Navi to be installed on Microsoft 32- and 64-bit Windows 7, XP and Vista to allow for easy migration between

Automated Test Outlook 2011: Key technologies and methodologies impacting the test and measurement industry This report details key trends, methodologies and technologies impacting test engineering organisations in every industry. The Automated Test Outlook combines input from academic and industry research, business intelligence and customer advisory boards. Read this white paper for more information.

systems, thus making it more cost effective and faster for multiple system integrations.

The Device Test Utility provides testing tools and parameter settings for analog input reading, waveform display and DO control. Information such as pin assignments, signal connections and specifications can be viewed from within the application as well. The integrated user guide contains programming reference material, example programs and introductory videos to help users get the most from this application.

Advantech Australia Pty Ltd Contact info and more items like this at wf.net.au/L639

Machine vision inspection: benefits, applications and vendor selection tips In recent times, the technology options for machine vision inspection systems have increased, the cost of these solutions has reduced and hence the adoption has dramatically increased. These solutions, if implemented wisely, can provide a competitive advantage for manufacturers as well as provide cost savings.

FANLESS PC SYSTEM ICP Electronics has

How to minimise losses in converter-fed induction motors This study presents a technique developed to minimise losses in totally enclosed fan-cooled (TEFC) induction motors fed by frequency converters in applications with constant torque loads, especially at low speeds, in which the ventilation system is inefficient.

announced the release of IEIâ&#x20AC;&#x2122;s Tank-800-D525 3-slot fanless embedded system.

The Tank-800-D525 comes fully equipped with an Intel Atom D525 1.8 GHz dual-core processor. The system supports multiconnectivity with four USB 2.0, one SATA 3 Gbps, two Gb ethernet LAN ports and six COM ports. Flexible PCI/PCIe expansion slots are provided to satisfy customisation requirements.

System memory is provided via a 204-pin 800 MHz DDR3 SDRAM SO-DIMM Slot (maximum to 2 GB), while onboard 1 GB of DDR3 memory is provided.

The Tank features an extended temperature fanless design supporting -20 to 70°C, a redundant dual 9-36 VDC input and a CompactFlash socket.

The Tank-800-D525 is suitable for installation on moving

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

objects with its antivibration and antishock design.

ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/P231

40 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

www.ProcessOnline.com.au

NEW PRODUCTS

HIGH-DENSITY WATERPROOF CONNECTORS

MODULAR SENSOR MOUNTING SYSTEM

Fischer Connectors has announced

The decision of where and

a high-density miniature circular inter-

how to locate a sensor is

connect solution. The Fischer MiniMax Series

often not made until the

increases the performance of rugged devices,

machine or equipment is

handling more mixed signal and power connections,

actually being constructed.

while saving space, weight and costs.

In-house fabricated fasten-

Fischer MiniMax Series offers high pin density,

ing systems can be expen-

housing a combination of twenty signal contacts

sive and time consuming,

(0.5 A) and four power contacts (5 A) in one single

so Balluff offers a line of

connector, providing three times more pins compared

sensor mounting fasteners

with standard Fischer connectors of a similar size.

for mix-and-match flexibility.

Its ultraminiature size saves more than 40% space

The fasteners are

and 75% in weight, compared with a standard Fis-

available in plastic

cherâ&#x20AC;&#x2122;s connector with similar pin count.

or V4A stainless

It is equipped with endurable keying as well as visual colour coding to

steel, making the mounting system suitable for use in challenging industrial environ-

avoid misconnection

ments and in automotive areas. The high quality stainless steel

and improve end-user

versions also provide resistance to industrial cleaning agents

safety. It also incorporates a reliable and user-

common in washdown environments.

The aluminium base holder fits nearly any manufacturer-specific mount-

friendly push-pull locking, or

ing extrusion and fully covers the slot. Also featured are knurled support

quick release system.

rods that provide a secure hold even for large, heavy sensors.

Fischer MiniMax Series is IP68

The system includes every conceivable accessory, including clamping

rated, even unmated, which makes

cylinders, cross-connectors and sensor holders for block-style and tubular

it suitable for underwater ap-

sensors, many designed so that, in their fastening function, they also

plications, even in cases of

provide mechanical protection for the sensor. Components such as

accidental disconnection.

reflector holders and adapter plates are also available.

It is also waterproof

Balluff-Leuze Pty Ltd

down to 120 m for a full

Contact info and more items like this at wf.net.au/L694

24-hour submersion.

Soanar Limited Contact info and more items like this at wf.net.au/L782

www.ProcessOnline.com.au

FEBRUARY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

AS I SEE IT INFORMAL TRAINING IS THE MOST POWERFUL FORM OF ENGINEERING EDUCATION

P

eople learn 70% of what they know about their jobs through informal means (US Bureau of Labor Statistics - 1996). So stop pouring your money into formal training without pausing to consider these other more powerful options.

Not through formal courses. Or training workshops.

Formal training accounts for only 20% of what people learn at work (according to Jay Cross). Was it money wisely spent?

In many cases, I doubt it. Our experience leads us to believe that a two-day short course is great. The instructor is often very good (and sometimes not so good).

The transfer of learning is outstanding.

Everyone understands the topic. But then no one applies the learning (and it is often difficult to apply to their jobs). After a few weeks, it is all forgotten - and so a completely wasted investment by the firm.

Great course manuals and great interaction with other professionals, but that is often where the learning stops.

Skills acquired informally are generally acquired by talking to others, watching what others do, by trial and error - and simply by osmosis, getting shown or corrected on a task they are struggling to accomplish.

Engineering apprentices know all about this form of learning in learning often from a master. Graduate engineers are supposed to engage in this form of informal learning from mentors but this is often still a work in progress and not particularly successful.

The most powerful form of training is to permeate your entire company culture with further informal learning by encouraging dissemination of know-how continuously.

For example, when a regular problem occurs and the bearing of a machine keeps seizing up or an alarm trips a part of the plant, identify what the problem is and then try to make the learning experience more generic so that the learning experience can be spread to other instances. Gather everyone around. All five technicians, the new snotty-nosed graduate engineer, the ancient manager about to retire - and then

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

spend five minutes showing them what went wrong and how to fix the problem.

And then get them involved in the learning process so that they can all demonstrate they understood what happened and won’t forget it. And get them to go and teach someone else in the firm. All informally and at low cost - and yet a very powerful learning experience.

A few suggestions in using informal learning: • List all the informal training activities that are going on in your firm. Publicise them, encourage and increase them.

• Permeate your whole work culture with the idea that informal learning is great and valuable. Do this from the top down.

• Build, promote and create informal communities of practice based anywhere from the water cooler to the internet.

• Improve meetings to make them learning experiences for everyone.

• Encourage open distribution of ideas, know-how and expertise.

Use your own people for informal learning - true engineering learning. And when you use formal training, ensure that you research both the need carefully and that it is applied to the job effectively, linking it in with your informal learning at your plant or office.

This true comment (along with thousands of others) is attributed to Albert Einstein: “I never teach my pupils; I only attempt to provide the conditions in which they can learn.”

Steve Mackay PhD CPEng, has worked mainly in the industrial automation and data communications fields for the past 30 years and is currently Dean of Engineering with worldwide engineering education business IDC Technologies (www. idc-online.com). Steve has also published over 30 engineering books, as both editor and co-author.

42 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2012

wnipt@westwick-farrow.com.au Chief Editor Janette Woodhouse Publisher Geoff Hird Art Director/Production Manager Julie Wright Art/Production Tanya Scarselletti, Katie Dean, Colleen Sam Circulation Manager Sue Lavery circulation@westwick-farrow.com.au Copy Control Mitchie Mullins Advertising Sales AUSTRALIA - Nicola Fender-Fox ph: 0414 703 780 nfender-fox@westwick-farrow.com.au NZ - Simon Skerman ph: 0800 44 2529 sskerman@westwick-farrow.com.au USA - Huson International Media East Coast ph: +1 212 268 3344 West Coast ph: +1 408 879 6666 ralph@husonusa.com UK - Huson International Media ph: +44 1932 56 4999 gerryb@husonmedia.com Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application.

If you have any queries regarding our privacy policy please email privacy@westwick-farrow.com.au

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

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.

www.ProcessOnline.com.au

www.processonline.com.au

Six of 500+ panels we built in 2011

Competence, capability, quality This picture shows six of the 500+ panels Bürkert Australia built in 2011.

Our Sydney Systemhaus is ISO 9001 certified for the ‘development, assembly and distribution of customised system solutions,’ making Bürkert the ideal partner for large and small scope projects. In addition to standard panels, we engineer custom panels with pneumatics, I/O, transmitters and programming designed to meet your wider control system needs.

Call on Bürkert to build your 2012 panels.

www.burkert.com.au | 1300 888 868 www.burkert.co.nz | 0800 BURKERT (0800 287 537)

We make ideas flow