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ON THE COVER
0213 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2013
Paperless calibration systems made with the combination of documenting calibrators and calibration software improves quality and cuts costs. The business benefits are significant for companies that use softwarebased calibration systems when compared with manual, paper-based systems. While using a manual, paper-based system requires little or no investment in new technology or IT systems, it is extremely labour-intensive and means that historical trend analysis of calibration results becomes very difficult. In addition, accessing calibration data quickly is not easy. Paper systems are time-consuming, they soak
CONTENTS 6
Choices in automated level detection
10
New products
12
Hot products online
22
Analyser sampling systems
38
As I see it
Choosing the right instrument for the job
Verifying fluid flow for reliability and accuracy
Become an engineering entrepreneur today
up lots of company resources and manual (typing) errors are commonplace. Dual effort and the re-keying of calibration data into multiple databases become significant costs to the business. The business benefits of a paperless calibration system are significant. The whole calibration process - from initial recording of calibration data through to historical trend analysis - will take less time, while mistakes and manual errors will be virtually eliminated. In turn, this means that operators, engineers and management will have more confidence in the data, particularly when it comes to plant audits. In addition, this greater confidence in calibration data leads to a better understanding and analysis of business performance and KPIs (particularly if the calibration software is integrated with other business IT systems such as a CMMS) leading to improved processes, increased efficiencies and reduced plant downtime. AMS Instrumentation & Calibration Pty Ltd www.ams-ic.com.au
NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.
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We make ideas flow
CHOICES IN AUTOMATED LEVEL DETECTION Glenn Johnson, Editor
PART 1
There are many technologies available today for the automated measurement of the level of a material in a vessel. All the available techniques work when applied correctly in the appropriate situation.
6 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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© iStockphoto.com/36clicks
T
here are many level measuring situations in which virtually any measuring technology will work, but there are also many cases where some technologies will work while most others will not. Generally speaking, it is a case of the more difficult the process environment or material, the more costly and complex the level technology. This article is an overview of those common technologies and techniques that can be considered ‘automated’ instrumentation. Manual level measurement gauges are not covered.
Head versus height Level measurement techniques can be categorised into two broad categories. One is ‘head measurement’, which is based on the force of the process material pushing down on a measuring device, and ‘height measurement’, which is based on measuring the distance to the upper surface of the material.
Head measurement For head measurement, there are two basic categories: one is the measurement of the weight of the process vessel or tank and the other is the measurement of the pressure applied by the material in the tank. Of these, measuring the weight of the vessel (usually performed with load cells under the tank supports) can give an accurate measure of how full the tank is, given that the density of the material is known - and it works for both solid and liquid measurement. The only risks of error here are electrical interference with the load cells, and vibration - the vessel needs to be shielded from vibrations, which may be transferred to the load cells, leading to spurious measurements. Measuring the pressure exerted by the contents of the tank is generally only suitable for liquids, but there are various methods of doing so, depending on the measuring conditions and material.
Height measurement Height measurement means measuring the distance of the top surface of the material (liquid or solid) from either the top (most common) or bottom of the vessel. Various forms of contact-based and non-contact methods are used, and some permit the detection of multiple levels simultaneously (liquid interface level measurement) where two materials of different density are present, one floating on the other. All methods have
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their pros and cons, and the correct method must be chosen based on the conditions of the process and the properties of the process material.
Point level versus continuous Sometimes we want to know the fill level of a vessel at all levels, to measure the quantity of material available. In other cases we are only interested if the level falls below a certain point, perhaps to trigger refilling, or if it exceeds a certain point, to prevent overflow, or to stop a filling process. The first is called continuous level measurement and requires a method that is constantly seeking or following the top surface level of the material. The second is called point level measurement and uses instruments or sensors located at appropriate heights in the vessel that are triggered when the material level passes that point - in other words there is a change of the conditions surrounding the sensor.
Challenges Depending on the liquid or solid to be measured, the design of the vessel and the conditions of the process, various challenges may be encountered. The design of the vessel must be taken into account, not only for its shape (in some cases the geometry of the vessel affects the level calculation), but also for internal structural features such as seams, supports and ladders, which may obstruct certain types of measurement. In some cases, the material may be so corrosive or flammable, or the vessel may be so hot or cold that no form of instrument can enter the vessel. In these cases, nuclear level measurement may be the only solution.
Solids For solids, the nature of the solid and the way it behaves in the vessel affect the measurement. Obviously, using head measurement by measuring the weight of the vessel eliminates all issues of the material properties, but this is not always practical, such as in the case of very large silos. Surface height measurement of solids presents various challenges: • Surface dynamics - The filling and emptying of the vessel results in a sloping top surface (the material has an ‘angle of repose’), that makes it difficult to determine the ‘average’ top level (Figure 1). Also, particle size has an impact on the
FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7
Level detection
Figure 1: Angle of repose.
Figure 3: Rotary paddle switch. (Source: Monitor Technologies)
Figure 2: Examples of tank bridle use. (Source: Magnetrol)
effectiveness of non-contact methods of measurement, due to uneven reflection of sound or radio waves. • Tensile forces - Forces in tall solids silos can reach many tonnes. As the vessel is filled or emptied, the material can cause damage to measurement devices. • Dust and noise - Dust filling the space above the material, as well as sound and electromagnetic noise, are common in solids vessels and can have detrimental effects on various types of measurement methods. • Material build-up - Some instruments are particularly sensitive to material build-up that can interfere with radio or electronic measurements or clog up moving mechanisms.
Liquids While liquids usually provide a nice flat surface for surface measurement, there may be other challenges surrounding the particular liquid that will affect what type of level measurement is used. • Corrosion - Some liquids are highly corrosive so contact methods of measurement may not be appropriate, since the liquid will damage the instrument. Corrosive vapours may also be present above the liquid, so non-contact instruments need to be protected. • Agitation - In some processes, the liquid is agitated in the vessel, or agitation occurs during filling and emptying, giving a moving level, as well as having impact on some types of measuring instrument. • Density change - Measurement methods that depend on a steady material density
may be affected by the change of density caused by temperature fluctuations. • Foam - Surface foam on a liquid (which may be there for various reasons, including agitation) can cause some non-contact methods to be inaccurate by presenting multiple interfaces. • Vapour - In closed vessels, vapour build-up above the liquid can cause interference with non-contact methods, and for some pressure-based head measurements, can cause increased pressure, resulting in a level reading that is too high. • Multiple interfaces - Some vessels will contain immiscible liquids of different densities, so that one tends to float on the other. Some methods of measurement are useful for detecting the interface level as well as the total level, but this depends on the properties of the liquids and the measurement method. • Material build-up - As for solids, some instruments are particularly sensitive to material build-up that can interfere with electronic and radio measurements or clog up moving mechanisms. For liquid applications, this can be a problem when the liquid is viscous or sticky.
Methods of interfacing With the exception of vessel weighing methods and nucleonic measurement, most methods of measurement involve some form of connection with the inside of the vessel, if not with the material itself.
have traditionally been configured. A bridle (also known as an isolating column or bypass pipe) is a vertical pipe connected to the side of the vessel, typically with two connections to the side of the vessel (high and low), or with one high on the side and one at the bottom (Figure 2). Because under most circumstances the fluid inside the bridle will rise and fall equally with the level of the fluid in the vessel, the bridle can be used as the location to apply the level instruments, although in most cases instruments are placed in their own bypass pipe or nozzle attached to the bridle. There are many advantages in using a bridle: • Fewer connections - The tank, once built with a bridle, need never be tampered with to add instrumentation. • Simpler changes - Changes to the instrumentation on the bridle do not affect the vessel. • Avoids obstructions - Internal structures in the tank have no effect on instruments attached to the bridle. • Overcomes turbulence and foam - In an agitated vessel, the bridle provides a calm surface for level measurement. It should be remembered that tank bridles do not always reflect the actual level. Examples may be where the level has exceeded the upper end of the bridle, or where two fluids are present, in which case the interface level in the bridle will probably not match the actual interface level, or may not appear in the bridle at all.
Tank bridles One more traditional way of attaching instruments in the case of liquid measurement is the same way that visual level indicators
8 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
Direct connection While non-contact methods of continuous level measurement such as radar can be
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Level detection Figure 4: Vibrating fork level switch. (Source: Rosemount)
Type
Point detection for liquids
Float
Yes
Point detection for solids
Paddle
Yes
Vibratory
Yes
Yes
Capacitance
Yes
Yes
Conductive
Yes
Radiometric
Yes
Yes
Table 1: Summary of point level switch applications.
used with tank bridles, in the case of solids measurement (and also many liquid measurement applications) an instrument may be mounted directly through an opening in the tank. In the case of liquid head measurement, this may involve the direct connection of one or more pressure instruments directly to the side or bottom of the tank. In this case, valves may be interposed for maintenance purposes. In the case of continuous height measurement for both solids and liquids, this will involve inserting the instrument though a hole in the top of the vessel. In this case, the risk of the detrimental effects listed above needs to be taken into account in each case.
Point level instruments The simplest application of level sensing is for detection of levels at fixed points for simple applications such as preventing overfill or run-dry, and to start and stop filling operations. All the point level instruments described below involve some element which protrudes into the process material and comes into contact with it.
Float switches Float switches use a float and magnetic switching action to switch when the float rises or falls with a liquid level. They are only suitable for liquids, and usually only for overfill detection, and come in vertical and horizontal orientations and can be top or side mounted. Their main advantage is their simplicity, but their disadvantage is the use of moving parts that can wear out, and the risk of seizing if they are not operated frequently. For this reason, they
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are not suitable for critical level detection, especially for hazardous liquids.
Rotary paddle switches Rotary paddles rotate a small paddle and the movement is disrupted when it comes in contact with the process material. They are only suitable for solids. Their main advantage is their simplicity, but their disadvantage is the use of moving parts that can wear out, and the risk of damage from forces exerted by some types of material.
Capacitance point level switches Capacitance type limit switches are static level sensors, use a sensing rod insulated from a ground sleeve. A capacitance is formed by the sense rod and earth extension, or the metal wall of a vessel. When no material is present, the capacitance is directly proportional to the probe dimensions and dielectric constant of air ( 0 ≈ 1). When material is present, the capacitance gets multiplied by dielectric constant of the material. This variation in capacitance is then translated into switching output by the device. The main advantage is that there are no moving parts, but the material being detected must have a dielectric constant different from air, and liquids must be nonconductive. They can also be detrimentally affected by static charges in silos.
Conductive point level switches Conductive limit switches work by inserting a rod into the vessel and applying an alternating voltage. In the simplest design, when an electrically conductive liquid contacts the probe it makes a circuit between the probe and the vessel wall. When the vessel is non-conductive, a version with an
integral ground probe can be used. Some designs have multiple probes with different lengths so that if suspended vertically they can detect multiple levels. Using alternating voltage prevents corrosion of the probe rods and electrolytic destruction of the product. They are only suitable for use with conductive liquids. The main limitations of conductive level switches are that contamination of the probes can prevent detection, and they may not be reliable if the conductivity of the liquid varies.
Vibrating fork level switches A pair of blades (or ‘tines’) is inserted into the process vessel and made to vibrate by a piezoelectric crystal oscillator. When the process material comes in contact with the forks, the resulting change in resonant frequency is detected. Their main advantage over a paddle switch is that there are no moving parts and they also work with liquids. Compared with capacitive or conductive sensors, the conductivity of the liquid medium is not relevant. However, some versions have very long forks that may be prone to being bent by heavy solids. They are not suitable for some very light materials such as ashes and build-up of material on and between the forks can cause inaccuracy, so the type of material is important in deciding whether to use them.
In Part 2 In Part 2 of this article, we will look at various technologies for continuous level measurement.
FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 9
NEW PRODUCTS
ANDROID INDUSTRIAL MOBILE DEVICE The IMX-2000 from Adlink Technology is an industrial mobile handheld device utilising the Android operating system. Combining high-performance RFID, barcode scanner and 3G/WLAN wireless transmission functions to satisfy diverse application requirements, the IMX-2000 can be applied in a wide range of industries. Applications include fully supported logistics management, transportation and factory automation. With an 800 MHz processor speed, as well as high resistance to impact, water and dust, the IMX-2000 has the capacity to enhance productivity and significantly reduce costs. The IMX-2000 utilises the Android operating system to offer a qualified and user-friendly interface. In addition, all the data can be conveniently input directly by numeric keys into the Android system. Designed with high-efficiency barcode scan processing capacity bundled with Reader Utility software, data saved under 1D or 2D barcode can be accessed easily. Wi-Fi, Bluetooth, GSM, GPS and AGPS are all integrated. Along with the robust design, the IMX-2000 passes IP65 and 1.5 m drop tests to ensure continuous operation after being inadvertently dropped and provides highly efficient operation even in extreme environments. With a 3.5″ resistive touch panel, the IMX-2000 is readable in sunlight for outdoor purposes. Equipped with a 5 MP back camera, the IMX-2000 supports wireless broadband for real-time video communication and surveillance. Also, the memory is expandable via microSD supporting SDHC up to 32 GB. With the rechargeable 3900 mAh Lithium battery, the IMX-2000 can provide long-term operation. A charging cradle is also provided along with the IMX-2000 for added convenience. ADLINK Technology Inc Contact info and more items like this at wf.net.au/S222
PROFINET IRT GATEWAYS HMS Industrial Networks has released a series of Anybus X-gateways that enable communication between several industrial networks and Profinet IRT. The X-gateways can connect Profibus and CANopen to Profinet IRT with fibre-optics, and ControlNet, EtherNet/IP and DeviceNet to Profinet IRT with copper cabling. They help plant owners and machine builders to migrate to Profinet without making changes to their existing machinery. The X-gateways copy I/O data between any industrial network and Profinet IRT. Gateway settings regarding, for example, I/O sizes are configured in a Windows-based terminal interface which means no programming is necessary. The Profinet interface of the X-gateway works as an I/O device on the Profinet IRT network and supports up to 220 B of I/O for both input and output data. The gateway’s baud rate is 100 Mbps (full duplex) and uses two RJ45 connectors (copper) or two SC-RJ connectors (fibre) allowing installations in line or ring topology. The integrated 2-port IRT switch eliminates the need for expensive external switches. Global Automation Asia-Pacific Contact info and more items like this at wf.net.au/R927
PROCESS CALIBRATOR The 7526A Precision Process Calibrator from Fluke Calibration is a benchtop process calibrator designed to simplify calibration of temperature and pressure process instrumentation by incorporating an isolated measurement channel, letting users source and measure simultaneously. It can be used to easily calibrate all types of sensors and instruments, such as RTD and thermocouple readouts, pressure gauges, temperature and pressure transmitters, digital process simulators, data loggers and multimeters. The calibrator simulates and measures nine RTD and 13 thermocouple types, accurately measures pressure to within 0.008% of reading when combined with Fluke 525A-P Series Pressure Modules, sources and measures DC voltage from 0 to 100 V to within 0.004% of reading, sources DC current from 0 to 100 mA, accurately measures DC current to within 0.01% from 0 to 50 mA and supplies 24 V DC loop power. Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/S016
10 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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Domino iTech
A tried&true way to LEAN your labelling and coding operations.
Domino introduces iTech: Common parts, software and control pads for all coding technologies. Today’s business is about LEAN operations, process improvement and achieving 100% quality. The new Domino iTech range allows users to control multiple technologies from a single touch point, and provides maintenance staff access to common parts for all equipment. Achieving LEANER operations, Domino’s iTech range allows the use of common parts, software and control pads for continuous ink jet, laser, thermal ink jet, thermal transfer overprint and print and apply technology.
Contact us to find out more about the Domino iTech range.
Phone: 1300 467 446
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Email: sales@insignia.com.au
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Web: www.insignia.com.au
HOT PRODUCTS
ON WWW.PROCESSONLINE.COM.AU THIS MONTH INTELLIGENT UPS The UPS-IQ mounting rail UPS power supply now has data communication capabilities for integration with control networks. Phoenix Contact Pty Ltd
>
DIGITAL PRESSURE SENSORS
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The AHLBORN FDAD33 and FDAD35M high-precision pressure sensors include an integrated A/D converter and signal conditioner. Bestech Australia Pty Ltd
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>
PXI EXPRESS CHASSIS
The NI PXIe-1085 PXI-Express chassis is claimed to be the industry’s first all-hybrid PXI Express chassis. National Instruments Australia
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> INLINE DENSITY METER
>
E-STOP PUSH-BUTTONS
The Anton Paar L-dens 427 density meter allows The expanded range of Pilz PITestop push-buttons is designed
users to upgrade a volumetric flow measurement
to make it easier to select the right E-STOP solution.
system to mass flow measurement.
Pilz Australia Industrial Automation LP
B-R Controls Pty Ltd
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12 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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NEW PRODUCTS
MICRO SERVO CONTROLLER
PANEL PC
Omron Electronics has released an updated series of m i c r o s e r v o c o n t r o l l e r s , t h e C P 1 L- E . B u i l t
The
Kontron V Panel Express panel
on the CP1L platform, the CP1L-E now offers
PC is now available with the Intel
an ethernet port, two analog inputs and pulse
Core i7 dual-core processor. Compared
I/O as standard features. A maximum of six
to its predecessors, this version offers nearly
100 kHz counter inputs (two with quadrature input)
double the performance and is suitable for industrial highperformance applications, with a processor speed of 2.2 GHz (2.9
and two 100 kHz pulse outputs can now be configured on all CPUs.
GHz in turbo mode) and up to 8 GB DDR3 memory.
The programming software incorporates a library of
With its 100% passive cooling concept, the panel PC needs neither a fan
function blocks to handle servo control functionality.
nor a fan filter to be replaced and is therefore completely maintenance free.
A range of functions is supported, including simple
Optimal shock, vibration and temperature resistance are all standard features of
absolute or relative moves and interrupt feeds. Simple
the panel PC family, as is EMI protection. The V Panel Express is available in
position control utilising a VSD is also possible, where
sizes from 12.1 to 19″, serving the increased demand for larger display sizes.
the control loop is closed through the controller, which
The front panel is made of stainless steel and offers IP65 protection against
utilises its built-in, high-speed I/O.
dust and water spray. The resistive touch display, with LED backlight, enables
CP1L-E CPUs are available in a choice of 20, 30 or
reliable operation even when working with gloves and pens. Optionally, the
40 I/O and support all the logic functions expected in a
front panel can be designed to cater to customers’ specifications, including
modern PLC. Programming is via IEC 61131 3-compli-
individual branding.
ant software and supports online editing. Expandability
For applications with less performance demands, a version is available with
is possible by the addition of extra modules or boards
the 1.4 GHz Intel Celeron 827E single-core processor. Interfaces include five
that plug into the CPU. External RS232 and RS485
USB ports, a 10/100 LAN port, a 10/100/1000 LAN port, two RS232 ports and a
communication modules can be inserted for Modbus
DVI-I video port. With up to two PCI Express slots, customer-specific extensions
RTU or other connections.
can be integrated. In terms of storage media, either up to two SATA hard disks
Omron Electronics Pty Ltd
or especially robust Compact Flash media can be housed.
Contact info and more items like this at wf.net.au/R807
Kontron Australia Pty Ltd Contact info and more items like this at wf.net.au/S294
OSCILLATION ANALYSIS Expertune’s PlantTriage software has been enhanced with tools to extend its oscillation analysis features. The software automates the engineering
PID CONTROLLER The Red Lion PAX2C PID controller is the most recent addition to the PAX2 Series. It is designed to improve flexibility and ease of use for process and temperature control. Applications can be found in the food and beverage, plastics, packaging, energy and gas industries, as well as in heat treatment and glass processing. The PAX2C has field-installable, plug-in option cards to simplify configuration by enabling customers to customise their own controllers. This type of flexibility eliminates the need to order additional products to meet changing application requirements. The dual-line, 3-colour display provides at-a-glance visual representation of up to 16 changing alarm conditions with seven programmable colour zones and is customisable to allow users full access to bar graphs, annunciators, colour zones and display mnemonics. The universal input accepts current, voltage, resistance, temperature and process signals all in the same unit, and the universal power supply accepts AC or DC power, and is ready to plug in ‘out of the box’ for fast, easy installation regardless of power polarity. Easy programming, firmware and software upgrades are performed using a built-in USB connector and Red Lion’s Crimson software to support both current needs and future requirements. Control Logic Pty Ltd
analysis, completing a Fourier transform and identifying key periods of oscillation. The software then filters the information so only the most likely sources of the problem will be identified. The oscillation analysis tools are fully integrated into PlantTriage’s web browser interface, and a preconfigured Problem-Solver report for oscillation analysis is included. The report can be viewed online, emailed, exported to Excel, or even scheduled for email delivery whenever PlantTriage finds a significant issue. No programming or SQL skills are required. The cycle detection and analysis tools are included with all PlantTriage systems, version 11.01 and higher. Existing PlantTriage users receive the features at no charge, as part of their software maintenance agreement. Daesim Technologies Pty Ltd Contact info and more items like this at wf.net.au/S295
Contact info and more items like this at wf.net.au/S274
14 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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NEW PRODUCTS
MOBILE BULK BAG FILLING SYSTEM The latest mobile bulk bag filling system from Flexicon features an integral metal detector/separator and a tilt-down conveyor/feeder for dust-free filling at multiple locations. The system detects metal in the free-fall stream of material entering the filler and then ejects it through a chute that discharges into a removable drum at the rear of the unit. The filler is also equipped with fill head height adjustment to accommodate all popular bag sizes; an inflatable cuff to seal the bag inlet spout; a blower to remove bag creases prior to filling; load cells for filling by weight; a vent port for dust-free air displacement during filling; pneumatically retractable bag hooks; and an automated vibratory densification/deaeration system to maximise capacity and stabilise the bag for storage or shipment. The first bulk bag filler to receive USDA acceptance, it is constructed of 316 stainless steel, finished to sanitary standards and configured with full-length forklifting tubes allowing it to be moved throughout the plant. The conveyor’s inlet hopper includes an air displacement vent with cartridge filter that is equipped with a reverse pulse cleaning system that dislodges accumulated dust with short bursts of compressed air, returning the dust to the hopper on a timed cycle, maintaining operating efficiency. The programmable controls are housed in a stainless steel NEMA 4X enclosure with touch screen that graphically displays filling functions. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/S133
Functional and safe processes Switch – convert – transmit with safety!
Higher reliability for your processes From relay module to threshold value switch – Phoenix Contact offers you certified products for easy expansion of safety functions. This means you are always on the safe side. Do you have any questions about functional safety? An addition to products, we also offer you training on this topic. For additional information call 1300 786 411 or visit phoenixcontact.com.au SEE US AT STAND i20
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NEW PRODUCTS
VALVE CONNECTORS Hirschmann has released the GDM series field-attachable valve connectors that can be used to supply power to components such as solenoid valves, pressure sensors and temperature sensors, or to connect them to a data network. Circuit protection ensures that downstream circuitry cannot be damaged by excess voltage or electromagnetic fields. Versions with built-in LED status indicators (with or without circuit protection) are also available. Depending on the version of the valve connector, additional features include IP68 protection, an operating temperature range of 40 to +90째C and high shock and vibration resistance. The type A connectors, also available with integrated strain relief conforming to UL 2238, are easy to connect due to their greater height. Depending on the connector version, cable diameters of between 4 and 14 mm with a conductor size of up to 1.5 mm can be used. The housings 2
are also characterised by features such as acid resistance or biodegradability. The easy-to-grip housings ensure safe
TEST MANAGEMENT SOFTWARE National Instruments has introduced NI TestStand 2012, the latest version of its automated test management software. With its modular process architecture, NI TestStand 2012 helps engineers increase the flexibility and throughput of their automated test systems, by making test set-up easier, expanding test and reporting flexibility, and making it possible for engineers to simultaneously test and report during parallel testing. Asynchronous result processing makes it possible to continue testing devices while simultaneously generating reports or data logging, and the plug-in architecture facilitates advanced customisations, including multiple report formats, with minimal code changes.
handling. The connectors are available with black or transparent housings, depending on the circuitry, and with two or three poles plus PE. The rated voltage is between 12 and 250 VAC/VDC, depending on the version, and the rated current between 1 and 10 A. Soanar Limited Contact info and more items like this at wf.net.au/S084
CONTROL LOGIC SIMULATION UPDATE MathWorks has announced an updated version of Stateflow in R2012b that simplifies control logic design. Stateflow Editor, state transition tables and MATLAB as an action language are designed to help engineers build applications like supervisory control, task scheduling and fault management more efficiently. Updated features include Stateflow Editor to access the Simulink model and Stateflow diagrams in the same window through tabs and, to assist with state diagram editing using smart guides, transition indicator lines, drag margins and just-in-time error notification. State transition tables are now available to build and edit state machines using a simple structured interface with automatic completion, syntax correction and diagnostic checks. Using MATLAB as the action language makes
NI Idea Exchange Community-requested features have also been included that reduce development time, including drag-and-drop code module files for step autogeneration,
it easy for MATLAB users to build state machines and flow charts, and the
and improved array and string manipulation.
integrated debugger helps step through logic and identify design problems.
National Instruments Australia
MathWorks Australia
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FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 17
NEW PRODUCTS
PLANT MOBILITY SOLUTION Honeywell has released Experion Mobile Access, a mobility application that provides secure remote access to Honeywell’s Experion Process Knowledge System (PKS) through mobile computing devices. Experion Mobile Access enables field operators to view
PROFIBUS/ MODBUS TCP GATEWAY
and respond to live information from Experion PKS while they are
The Moxa MGate 5101-PBM-MN
on rounds or inspecting the plant.
gateway provides a communi-
To meet plant and field operators’ need for fast and easy ac-
cation portal between Profibus
cess to plant data, the company has developed Experion Mobile
devices (such as Profibus drives or
Access, which works securely with the Experion PKS architecture
instruments) and Modbus TCP hosts. All
and the company’s OneWireless Network. This software applica-
models are protected with a rugged metallic casing,
tion provides seamless field data access for plants with complex
are DIN rail mountable and offer optional built-in optical isolation.
processes and expansive footprints that rely on a large mobile
The rugged design is suitable for industrial applications such as
operator staff for proper operations, and to support the availability
in oil and gas, power, process automation and factory automation.
of process equipment.
Moxa’s AutoScan function can automatically detect all connected
It is designed to help field operation teams find and avert process
Profibus slave devices and their available I/O modules to quickly
conditions that could affect production output. Recent cases stud-
complete gateway configuration, after which an easy-to-read data
ies have shown that an average-sized refinery or chemical plant
mapping table is created to assist in the configuration of Modbus
can see up to $1 million per year in savings, a 15% improvement
TCP master settings.
in mean time between failure of assets and a 10% reduction in
The MGate 5101-PBM-MN provides a web console and telnet
maintenance costs.
console for remote maintenance. Each also supports encrypted
Experion Mobile Access leverages Experion Distributed System
communication protocols such as HTTPS and SSH for preventing
Architecture (DSA), including Experion eServer technology to deliver
unauthorised access.
data to field operators throughout the facility. Its web-based user
The MGate 5101-PBM-MN has dual power inputs for greater
interface has been optimised for small mobile devices, such as
reliability. This higher level of reliability makes these Profibus
industrial handhelds commonly employed by workers during their field
master to Modbus TCP gateways suitable for demanding indus-
rounds, but also other devices such as smartphones and tablets.
trial applications.
Honeywell Limited
Madison Technologies
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ROBOT MOTION CONTROLLER Adept Technology has announced its latest SmartController EX. This lead-free, high-performance distributed motion controller, designed for use with Adept robots, features a high-speed processor and updated software. With more processing power and faster communication, the controller can increase a robot’s cycle speeds by up to 5%. The product features Gigabit ethernet and a processor that is 10 times more powerful than the previous generation. Four times more memory further enhances performance and the 2 GB SD memory card slot adds functionality, allowing users to easily transfer data between controllers, capture log data and back up data to a PC. The controller’s Adept eV+ software is built around a robust real-time operating system. It is seamlessly backwards compatible with V+ code and integrates with Adept’s vision-guidance technology for optimal robotic performance. The company designed the controller for use with Cobra s-series SCARA robots, Viper six-axis robots, Quattro parallel robots and Python Linear Modules. It is backwards compatible with the company’s CX controller - users can use the same connectors and code and easily transition. The product comes with an optional T20 Pendant. This handheld device provides a user interface in an ergonomic and rugged package. Designed for both right- and left-handed users, the gripping and holding positions enable comfortable, fatigue-free operation. Compared to previous generation pendants, the T20 is lighter and features a more colourful interface to ease use. Adept Technology International Ltd Contact info and more items like this at wf.net.au/S030
18 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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For 75 years, We’ve helped engineers keep the World running To win a trip to the FA Cup Final, visit www.rs-components.com/75
We help engineers keep the World running
SINCE 1937, PUTTING OUR CUSTOMERS FIRST HAS MADE US THE WORLD’S NUMBER ONE* 2000
1990
Electrocomponents PLC joins the FTSE 100 Index of the UK’s largest companies.
International expansion into Asia and Europe begins.
1937
1998 1937 JH Waring and PM Sebestyen establish Radiospares in London.
WHEN THE WORLD COUNTS ON ENGINEERS, THEY COUNT ON US
Our fully transactional B2B website – a UK industry first – supports fast, 24/7, hassle-free orders of electronics and maintenance products.
Transforming imagination into reality One of the world’s leading film effects companies, New Zealand-based Weta Workshop has partnered with RS Components for over a decade. The effects specialists behind the Lord of the Rings, Avatar and the upcoming trilogy, The Hobbit, Weta Workshop is a multi-award-winning conceptual design and physical manufacturing facility that serves the world’s entertainment and creative industries. Jon Ewen, Purchasing Officer at Weta Workshop, says, “The main reason we turn to RS Components is that they have such a wide range of products all in one place.” What’s more, RS Components’ quick delivery times means that most orders arrive the next day, which is vital in the film industry. The nature of Weta’s work means that they have a wide and varied requirement, as no two projects are ever the same. With an unrivalled range of electronics and maintenance products, RS Components is perfectly placed to meet this need.
“WITH SUCH A WIDE RANGE OF PRODUCTS, RS CAN OFFER ALTERNATIVES THAT KEEP US MOVING FORWARD.”
Jon Ewen Purchasing Officer, Weta Workshop Wellington, New Zealand
2002 We are first to market with a free e-Procurement tool, RS PurchasingManagerTM, saving businesses time and money.
2012 RS Components wins Britain’s most coveted business award, the ‘Queen’s Award for Enterprise’.
2012
2011 Now dispatching one parcel every two seconds, we receive the ‘Operational Excellence Award’ at the prestigious Supply Chain Distinction Awards.
Innovative solutions for forward-thinking businesses Through an enduring commitment to exceptional service, RS Components enables companies like KK Electrical to work smarter and more efficiently. The New Zealand-based electrical contractor relies on us to supply its specialist automation requirements. Owner Ken Sullivan says the benefits RS Components brings to his business are absolute supply certainty and quick next-day delivery#. “My local wholesaler just can’t compete with that. They might promise overnight delivery but that is rarely the case and while I might save a few bucks, it’s nothing compared to the cost of having my guys stand around idle waiting for parts to materialise,” says Sullivan.
“WHEN I ORDER THROUGH RS COMPONENTS, I KNOW EXACTLY WHAT I’M BUYING AND WHEN I’LL GET IT. THAT ALLOWS ME TO PLAN PROJECTS WITH CERTAINTY AND MEET MY COMMITMENTS.”
Ken Sullivan Owner, KK Electrical Christchurch, New Zealand #
* RS Components is the trading brand of Electrocomponents, the world’s leading high-service electronics and maintenance distributor with sales revenue of £1.27 billion as of 31 March 2012.
As the leading high-service distributor of electronics and maintenance products globally, we provide:
Widest range online & in stock Same-day dispatch, on-time delivery Expert local language support Smart search, tools & platforms Latest leading technologies Flexible order quantities
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FOR ALL YOUR ELECTRONICS AND MAINTENANCE NEEDS, VISIT www.rsaustralia.com www.rsnewzealand.com
Please refer to your local RS online site for local delivery terms and conditions.
WE HELP ENGINEERS KEEP THE WORLD RUNNING
ANALYSER SAMPLING SYSTEMS VERIFYING FLUID FLOW FOR RELIABILITY AND ACCURACY Sam Kresch, Product Manager, Fluid Components International (FCI)
No matter how sophisticated a fluid analyser system may be, it will be ineffective if a sample flow fails to reach the analyser sensor or if the sample is contaminated or stale. The most advanced systems in the world cannot provide accurate results without a valid fluid sample.
G
as chromatographs, mass spectrometers, optical spectrometers and photometers are a few examples of analyser technologies applied in process and plant systems that need sample flow assurance. It is an accepted industry best practice that sampling systems have some type of flow monitor to assure valid samples and analysis. Failing to monitor fluid flow to the analyser may result in contaminated product batches and discharging regulated substances. The costs of analyser failure are potentially huge in terms of affecting product materials, damage to equipment, regulatory fines, liability and more. While there are a number of fluid flow monitoring technologies on the market, immersible thermal dispersion technology combined with packaging and sensor designs optimised for sampling systems has emerged as the new best-in-class technology. Thermal dispersion mass flow sensors have proven themselves for decades to be extremely reliable in other demanding process and plant applications - often in relatively close proximity to analyser systems.
22 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
Recent developments The trend towards mounting the sample-handling system at the process has greatly enhanced process efficiency. Recent developments in packaging and speed now make it possible to run analyser systems more efficiently, utilising the real-time information to process online in batch mode. Developments in continuous flow reactors combine with analytics and new sampling systems to improve reaction times. More and more systems now provide analysis of the process in real time, making the integrity of the readings that much more important to the process success. The ideal flow monitor should provide the form, fit and functions that will accommodate both these new-generation analyser systems and traditional legacy and hybrid designs (Figure 1). Depending on the analyser type, sampling fluid is often transported in 1/8″ to ½″ tubing. Most systems typically draw small samples in ¼″ tubes. Also growing in popularity are systems based on the industry-standard SP76 manifold. SP76 is an ANSI/ISA standard approved in 2002, which is supported and has been adopted worldwide by major chemical and refining companies (Figure 2).
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Instrumentation & sensors
Flow technologies
SP76 and NeSSI basics Leading the way for the SP76 standard is the New Sampling/ Sensor Initiative (NeSSI) organisation, initially created in 1999 through discussions in a Center for Process Analytical Chemistry’s (CPAC) oil and petrochemical focus group. Other organisations have embraced and are promoting NeSSI/SP76, including the International Forum for Process Analytical Chemistry (IFPAC) and the Federation of Analytical Chemistry and Spectroscopy Societies (FACSS). Each block of a typical SP76 train is 1.5 x 1.5″ square and effectively becomes a convenient plug-and-play modular surfacemount interface for numerous sampling system components (Figure 3). The NeSSI group remains active in advancing enhancements for the process analysis community. Beyond the initial physical interface of the SP76 manifold itself, the group has defined progressive levels of sophistication, known as Gen. I, II and III, that provide for digital bus communications, hazardous location approval types and the Sensor Actuator Manager (SAM).
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Regardless of the analyser fluid sampling system configuration, flow monitoring is essential to ensure proper analyser operation. There are numerous methods and technologies available to monitor sample flow on a real-time basis. These can be mechanical spring or gravity loaded pistons, variable area types, differential pressure and thermal mass flow. In most cases, a simple relay contact or solid state output change is all that is desired to indicate a reduction or absence of flow at a predetermined setting. A recent trend is driving the output requirements to include an analog or digital communication signal to monitor the sample flow rate throughout the flow range. This allows operators to better predict flow declines due to disruptions caused by clogging filters, line contamination from fouling fluids, leaky or failing pumps, and other time and wear susceptible components in the system. Mechanical devices normally have the advantage of not requiring power to operate; however, a minimum number of wires are still required to transmit an electronic signal (contact closure) back to the control system. As these devices are triggered by the force of the flow stream such that specific and fixed application details, including the sampled fluid’s density, viscosity, temperature, pressure, flow rate and, if non-adjustable type, the trip point, must be known and be specified when ordering them. Furthermore, because springs, magnetic components and seals are all in the wetted flow stream, their material compatibility must also be evaluated by the specifying engineer. While mechanical devices with factory fixed trip points can be one of the lower priced solutions, those with adjustable trip points are often double the cost and approaching the price of some of the more robust and sophisticated technology solutions mentioned later. The leading drawback and most frequent user issue with these mechanical devices is their susceptibility to sticking over time. As all mechanical designs have moving parts in the flow stream, contaminating fluids can be a serious source of future failure. Fouling contaminants can progressively build up over months or years and are only detected when other failures in the system are detected. These devices can also have nooks and crannies that are exposed in the flow stream as they displace the flow path volume. In addition to being another area subject to clogging, they can trap previous samples or purge media which can contaminate subsequent samples. Piston-actuated devices also have no continuous visual indication of normal or abnormal flow conditions for the operator, other than their preset trip point.
Variable area meters Variable area meters have the advantage of continuous visual display of flow; however, they are also susceptible to sticking over time in many fluids. Their longer term reliability is often a concern
FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 23
Instrumentation & sensors
REGARDLESS OF THE ANALYSER FLUID SAMPLING SYSTEM CONFIGURATION, FLOW MONITORING IS ESSENTIAL TO ENSURE PROPER ANALYSER OPERATION.
Figure 1: Typical sampling system. expressed by analyser users. Adding a magnetic pickup to provide an electronic relay trip or an analog output adds significantly to their cost. Variable area meters tend to take up more valuable enclosure space than desired as they are very orientation dependent; and their flow input and output access are typically on different planes. Differential pressure (DP) devices can be a sound technology to monitor analyser flow rates. Even in the small line sizes and at very low flow rates associated with analyser sampling systems, a properly sized orifice and sensitive pressure transducer can yield desirable results. The two main disadvantages of DP technology are: 1. Its limited flow rate turndown capability. 2. The large errors incurred at the low end of the flow rate readings. Very often it is the low end that is critical for sample flow assurance and flow monitoring in analysers and sampling systems. Unfortunately, optimising the flow range to the low end of DP sensors can result in an appreciable pressure drop and poor flow measurement performance at normal flows. Similar to piston-driven switches and variable area meters, DP flow monitors must be selected knowing the density and a specifically narrow flow rate range of the sample process. There are limited DP devices designed for the SP76 manifold. They require at least two block spaces and are the most expensive of all the monitoring devices.
Solving the problems An ideal flow monitor for an analyser sampling system would be one that can be adapted on site and adjusted specifically in the application. In addition, a more robust flow sensing technology married to flexible and user programmable electronics, which can be specified without detailed and finite validation of process variables such as density, viscosity, flow range, fluid type, etc, also would alleviate a pain point for the analyser system supplier and site engineering team. Flow monitors designed with thermal dispersion technology match up extremely well with the ideal universal use criteria to support an analyser sampling system. Depending on the manufacturer’s flow element and electronics design, they can be set up by the user in situ to assure the field engineer a successful, first time correct installation. These devices may be configured in the field to operate in
24 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
Figure 2: FCI FS10A mass flow meter mounted on an SP76 manifold.
gases or liquids at almost any density or viscosity with no special consideration at time of ordering. There are two major types of thermal devices on the market. One type utilises a capillary bypass technique and is better known as a mass flow controller or MFC. MFCs divert a portion of the main flow into a small bypass and sense the heat transfer of flowing fluid in the bypass channel. This technique can be very effective; however, the capillary tube is highly susceptible to contamination and clogging and should only be considered for use with clean or pre-filtered fluids. Capillary bypass flow monitors are generally applied in lab use, and agency approvals (eg, FM, CSA, ATEX, IECEx, etc) for use in hazardous, explosive environments are rare. Flow range selection is also important when specifying MFC type flow monitors.
Immersible thermal dispersion technology The other type of thermal dispersion flow monitoring device is one that uses thermowells in the flow stream, sometimes referred to as immersible-type. These types of devices typically apply heat to one thermal sensor relative to a second thermal sensor measuring the process temperature. The temperature difference changes with flow rate. In the case of gases, the measurement is directly related to mass flow. Immersible thermal flow monitors are very effective over wide
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Instrumentation & sensors
Figure 4: FCI FS10A mass flow meter mounted in a tube tee.
Figure 3: Integral mounting on an SP76 platform.
flow ranges in gases and over smaller low flow ranges in liquids. Thermal technology is particularly advantageous in process analyser systems because it has no moving parts to wear, stick or foul. With their tiny thermowells and wetted materials typically made of 316L stainless steel or Hastelloy alloys, they are highly compatible and well suited to application in most analysers and sampling systems. The thermal probe can be threaded into industry-standard tube tee branches (eg, Parker, Swagelok, Circor) (Figure 4) or even into a single block in the previously mentioned SP76 manifold, resulting in minimal dead space. There are no cavities to trap previous samples so sample integrity is always the highest. Another key characteristic of thermal flow monitors for analyser applications is their superior sensitivity to low flow rates. It is not uncommon to find analysers requiring preheated or hot process fluids. As thermal devices typically do not require elastomer seals, and can be easily configured with the sensor element and electronics separated (remote), they are often the best and only solution for higher temperature service requirements - up to 260°C is common. Other features may include indicators or displays of trip point status and flow rates, isolated SPDT alarm contact and analog or digital output to monitor flow trends. Perhaps the most important benefit of some types of thermal devices is their ability to be field set and field adapted by the user for inexact, unknown or changed process and application conditions. Precisely and completely defined process conditions and fluid variables are often lacking during the preliminary design and engineering phase. Variations in tubing configuration, flow direction layout, ambient and fluid temperature conditions, pressure and density variations, viscosity, flow range, fluid type and trip points are variables that are often only finally determined after installation and site commissioning. Thermal dispersion flow technology-based products with smart electronics can provide maximum field adjustability and site adaptability.
Conclusions
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FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 25
Flow sensors and monitors are just one of the components required in complex process analyser and sampling systems. While there are several flow monitoring technologies available that can be considered, their diversity can make proper selection a major challenge. The question becomes, which flow technology is optimum for the particular type of analyser application and its operating environment? Properly selecting a flow sensor for an analyser sampling system can take an inordinate amount of an engineer’s time because of the complex factors that must be reviewed. Consideration must be given to: • diversity in measuring range • fluid type and condition compatibility • temperature and pressure condition suitability • outputs and user interfaces • approvals for Ex locations • site adaptability and adjustability • tube tee and SP76 compatibility • dimensions, weight and orientation • total installed cost Even then there is still worry about whether or how well the chosen flow monitor really functions when the system is commissioned, launched and put into operation. A flow monitor that is adaptable and can be site set for most any field condition variables, such as those based on immersible thermal dispersion technology, provides maximum confidence that the analyser system will perform as expected upon installation. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/S722
270x88mm HACH PACIFIC_PROCESS TECH:8.25x10.75 WEAU OPT
1/8/13
7:13 AM
Page 1
INSTRUMENTATION & SENSORS PRODUCTS
Your analysis has to be right.
YOU DESERVE COMPLETE SOLUTIONS YOU CAN BE FULLY CONFIDENT IN.
MARKLESS LABEL SENSOR Though used like a print mark sensor, the Sick ML20 sensor requires no optical marking on the package, instead detecting a taught-in design pattern. In future, the label on beverage bottles or chocolate bars and packaged chips can be in the right spot even without a registration marking. The ML20 uses a novel method for detecting contrast patterns. In the process, the sensor is taught a pattern sequence, eg, the graphic images or lettering, which is then detected at a scanning rate of up to 7 m/s, resulting in the output of a switching signal. Even if the labels have a complex design or the machine is operating at high speed, the ML20 detects nearly any pattern with accuracy and stability.
Hach is your resource for expert answers, outstanding support, and reliable, easy-to-use products.
The metal housing of the sensor provides a high level of ruggedness, and it is easy both to integrate
AUS: 1300 887 735 NZ: 0800 50 55 66 hachpacific.com
in machines and to commission. The sensor works reliably even if the image patterns are intricate or the process varies. When changing label or foil reels, the sensor avoids unnecessary cutting loss and waste, since pattern recognition is active right away, enabling use of the material starting immediately after the beginning of the reel. In some packaging processes, for instance when labelling bottles, there are additional savings of the additional material previously used exclusively for the print mark. The markless technology allows savings up to 5% of material per label. Sick Pty Ltd Contact info and more items like this at wf.net.au/S270
26 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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INSTRUMENTATION & SENSORS PRODUCTS
THERMAL MASS FLOW METERS SUBMERSIBLE PRESSURE TRANSMITTER FOR LEVEL MEASUREMENT The LH-20 submersible pressure transmitter is a slender, high-performance instrument, with a diameter of only 22 mm and an accuracy of up to 0.1%, even in harsh operating conditions. As a result of numerous options and functions, the level probe is suitable for almost all applications in level measurement with full media contact. The LH-20 exhibits a very low temperature error and is available with a parallel temperature output signal, HART communication and a scaleable measuring range. For the highest resistance to media, the probe is available in a stainless steel or titanium version, with PUR, PE or FEP cable. In the specific design variant for drinking water applications, the device meets the KTW and ACS regulations for drinking water conformity. The probe is also available in an explosion-proof version. WIKA Australia Contact info and more items like this at wf.net.au/S405
Sierra Instruments has introduced the QuadraTherm 640i/780i thermal mass flow meter series. With its sensor design
CAPS
PLUGS
COVERS
MASKING
advancements, coupled with a proprietary iTherm algorithm, the 780i inline version achieves gas mass flow rate measurement accuracy of ±0.5% of reading above 50% of the full scale (air). Traditional thermal sensors have two sensors - one temperature sensor and one velocity sensor, each in a separate probe. QuadraTherm introduces four sensors - three precision platinum temperature sensors and one no-drift DrySense mass velocity sensor, which uses a proprietary manufacturing process to improve accuracy and long-term stability. The QuadraTherm sensor isolates forced convection (the critical variable for measuring gas mass flow rate) by calculating and then eliminating unwanted heat-transfer components like sensor stem conduction, one of the major causes of false flow readings. The result is a fundamentally different gas mass flow rate calculation using all pertinent variables for a precise, stable and accurate thermal mass flow measurement. The product is available in two models: the 640i insertion and 780i inline. The range has a no-drift sensor and a multivariable output for mass flow, temperature and pressure (optional). It measures all inert and all non-condensing clean gases as well as flammable gases (methane, propane, hy-
Nobody has a greater range of Flexible Vinyl Caps and Plugs than STOCKCAP. And they’re in stock now for immediate delivery. Ideal to protect, mask or insulate components from shipping, storage or processing damage, STOCKCAP Flexible Vinyl Caps and Plugs fit snug to seal out moisture, oil and dirt. Choose from thousands of sizes, shapes and colours all at the industry’s most competitive prices. So if you need Caps or Plugs in stock, get ours ex-stock.
drogen, and digester gas). Repeatability for mass flow rate is ±0.15% and gas accuracy is ±1°C. Procon Instrument Technology Contact info and more items like this at wf.net.au/S390
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FOR FREE SAMPLES AND A CATALOGUE CALL Sinclair & Rush Pty Limited 51 Wellington Street Riverstone NSW 2765 info@sinclair-rush.com.au Fax: (02) 9627 5156 Tel: (02) 9627 3211
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FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 27
INSTRUMENTATION & SENSORS PRODUCTS
RH AND TEMPERATURE TRANSMITTERS Maintaining reliable RH measurements in harsh or corrosive environments is notoriously difficult as the conditions themselves degrade the sensors and equipment, often in short tim periods. To provide a solution to this problem, Michell Instruments has released the DT722 RH and temperature transmitter. To best meet specific application needs, the DT722 series is available in digital (DT722) and analog (DT722-X18) models. The digital electronic platform version gives high-performance measurement and RH accuracy and delivers reliable, consistent and accurate results even over changing ambient conditions. The DT722-X18 is an analog through-path measurement device with high mechanical toughness. Field adjustment is quick and easy, making it a good choice for use in all types of aftermarket service and it is already in service in the nuclear industry. The transmitters have been designed for use in severe industrial environments. They offer a strong, stainless steel housing providing protection against rough handling or accidental damage, IP65 (NEMA 4) ingress protection, and a probe that can withstand temperatures up to 150°C. The transmitters are for duct mounting in the most suitable place for the application. They have high chemical resistance for longer use in contaminated areas and are available with a selection of filter COMPONENTS materials to afford best protection to the sensors based on specific environmental conditions. AMS Instrumentation & Calibration Pty Ltd
CONTROL
Contact info and more items like this at wf.net.au/S447 COMPONENTS
Control Components Control Components
SENSORS FOR HYGIENIC ENVIRONMENTS
CONTROL COMPONENTS
Level Control
The Banner Engineering QM26 and QMH26 photoelectric
Control than sorry Components
and pharmaceutical industries. The sensors’ design con-
BESTA safe
Explosion Proof Level Switches IECEx Certified
sensors are designed specifically for the food and beverage siders Hazard Analysis and Critical Control Point (HACCP) principles for hygienic manufacturing processes, and they are designed to work in areas where the sensors may come in contact with food or materials. They are suitable for harsh washdown environments with high pressure, extreme temperatures and chemicals. The QM26 is housed in a non-toxic 316L stainless steel housing and can survive high-pressure washdowns and temperature cycling, ranging from -30 to 60°C. The sensor
Trimod BESTA LEvEL SwiTchES • Hazardous versions IECEx : • Ex ia Intrinsically Safe Group II Zone 0/1
is ECOLAB certified for inexhaustible sensor life in chemically cleaned environments and is intended for splash zone areas. The QM26 also features easy side-mounting for quick set-up and installation. The QMH26 has all the advantages of the QM26; however,
• Ex ed Flameproof enclosure Group II Zone 0
it is designed with minimal grooves and crevices, leaving
• 3 modular concept. Unlimited Switch designs
no room for bacteria to hide and multiply. It is self-draining
• Industrial / Mining / Petrochemical / Marine
for clean-in-place (CIP) applications. The sensor’s hygienic mounting shape reduces contamination risk, making it a suitable sensor to place in contact zones.
TAKE CONTROL
CCEZY.COM.AU
Micromax Pty Ltd Contact info and more items like this at wf.net.au/S478
02 9542 8977
28 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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INSTRUMENTATION & SENSORS PRODUCTS
MECHATRONIC FLOW SENSORS FLAMEPROOF TEMPERATURE TRANSMITTERS AND ASSEMBLIES Moore Industries’ temperature transmitter assemblies are certified ANZEX Ex d IIC T6 for use in flameproof (explosion-proof) applications. Transmitters are approved with spring-loaded and fixed sensors specially designed to meet stringent certification requirements. The springloaded sensor model is used to push and hold the temperature sensor probe tip securely at the bottom of the thermowell. The fixed sensor model probe is permanently welded to the bottom of the nipple when the assembly is installed without a thermowell. Analog and smart ready-to-install temperature assemblies are available with a wide variety of RTD and thermocouple sensors, thermowells and fittings. Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/R985
ifm efector’s SBT series mechatronic flow sensors can be used for flow ranges from 0.3 to 25 L/min at pressure ranges of up to 15 bar. The sensors function on the principle of the spring-supported piston: the piston, located in the valve seat in the housing, is lifted by the flowing medium against the spring resistance. The mechatronic measuring principle enables response times of less than 10 ms. At the same time, the spring resistance forces the piston to return to its original position with decreasing flow. This ensures position-independent installation of the flow sensor, preventing backflow. Due to the temperature decoupling of the transducer from the electronics, some versions of the sensor are suitable for media in high-temperature applications of up to 180°C. The sensors can be set intuitively and provide an analog output signal. ifm efector pty ltd Contact info and more items like this at wf.net.au/S365
SMART PRESSURE TRANSMITTERS Honeywell SmartLine pressure transmitters are designed to make it easier to support field devices and promote plant reliability with their efficiency-enhancing features, such as a graphic display capable of showing process data in graphical formats and communicating messages from the control room. SmartLine transmitters also feature modular components to simplify field repairs and reduce inventory required to make those repairs. The display supports graphical process data in easy-to-read trend lines and bar graphs while also providing a platform for operator messages, comprehensive diagnostic warnings and loop status for maintenance. These capabilities are part of the transmitter’s Smart Connection Suite, and allow control room operators to send messages to the display to make it easier and faster for field operators to identify the correct transmitter and determine required maintenance tasks. When integrated with Honeywell’s Experion Process Knowledge System (PKS), the transmitter can also display its maintenance mode - telling field operators if the control loop is in a safe state to perform maintenance. Installation is made easier with the smart display - three buttons at the top of the transmitter are used with the graphic display to completely configure the transmitter with no external handheld devices required. The modular design streamlines maintenance by allowing replacement of individual transmitter components instead of the entire unit, even in hazardous locations. This design reduces plant life cycle costs by providing purchasing flexibility, lowering inventory costs and reducing maintenance and repair work. Other safety and efficiency features include enhanced security alerts and wiring polarity insensitivity. Honeywell Limited Contact info and more items like this at wf.net.au/S238
30 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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Two GreaT Companies. one BriGhT FuTure. How do you create a global company built for the future? By combining two powerful histories in pursuit of a bold vision—to help companies around the world contribute to healthier, safer environments. Building on the achievements of Pentair and Tyco’s Flow Control businesses, comprised of Valves & Controls, Thermal Controls and Water & Environmental Systems, the new Pentair delivers exceptional depth and expertise in filtration and processing, flow management, equipment protection and thermal management. From water to power From energy to construction From food service to residential We’re 30,000 employees strong, combining inventive thinking with disciplined execution to deploy solutions that help better manage and utilize precious resources and ensure operational success for our customers worldwide. Pentair stands ready to solve a full range of residential, commercial, municipal and industrial needs.
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INSTRUMENTATION & SENSORS PRODUCTS
INDUCTIVE LINEAR POSITION SENSOR
AERATION ANALYSER Endress+Hauser’s Liquiline CDC80 optimises aeration times in the biological stage of wastewater treatment. This is the stage that is energy-intensive as most oxygen blowers are operated in a time-based manner or using only a simple form of oxygen control. The analyser allows the aeration process to be run according to the wastewater ammonium load, which is far more efficient. It monitors ammonium load and
The Turck LI inductive linear position sensor has an enhanced
controls the oxygen blowers so the aeration process
electronics architecture that increases the effective output rate
only runs until the ammonium value has reached a
of the sensor from 1 to 5 kHz. In conjunction with the short signal run time
predefined lower set limit.
(130 µs) and the highly resolved SSi output, the inductive linear position sensors
The product also determines the oxygen setpoint
can achieve the performance of potentiometers but without their disadvantages.
value, which is adjusted dynamically depending on
Unlike potentiometers, the LI sensors offer permanent protection to IP67,
the ammonium load, so the plant can be attuned
provide non-contact measuring and are wear-free. The magnetic field im-
to different load situations. This leads to optimised
mune sensors are suitable for measuring axes with high-speed controls
operating times for nitrification and denitrification, and
such as those used in injection moulding machines. Other application areas
reduced energy consumption. Phosphate precipitant
include axis measurement in packaging machines, presses or machine tools.
dosing can also be controlled by the device, ensur-
With the high speed and precision of the sensor (system resolution of
ing efficient phosphate conversion and saving on
1 µm), machine builders can keep the position error in motor control ap-
precipitant and costs.
plications to a minimum. As with all inductive linear position sensors, the
The product can connect to existing instrumentation
high-speed variant has very short blind zones and can tolerate up to a
and be easily integrated into existing process control
4 mm offset of the positioning element (perpendicular to the measuring
systems. Additionally, if the company’s Memosens
axis). As well as the high-speed variant with an SSI interface and 16-bit
technology is used, calibration values and measured
resolution, the analog variant of the sensor will also be offered in the future
values can be digitally transferred to the transmitter
with the higher output rate of 5 kHz. The analog sensor has a 0-10 V or
without interference. A remote access function is
4-20 mA output. All LI sensors continue to be available in 10 measuring
available for even faster and easier maintenance - a
lengths from 100 to 1000 mm. An 8-pole M12 connector is used for the
safe VPN channel allows monitoring and change of
connection.
parameters.
Turck Australia Pty Ltd
Endress+Hauser Australia Pty Ltd
Contact info and more items like this at wf.net.au/S207
Contact info and more items like this at wf.net.au/R423
32 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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Slicing cheese with automated precision New Zealand boasts a world-class dairy industry with annual exports in excess of NZ$11 billion. This success can be largely attributed to technological advances in both farming practices and manufacturing techniques. Key strengths of NZ’s dairy industry include its all-grass farming system, large-scale processing and high levels of R&D. With a reputation for providing products that comply with rigorous health and safety standards, the NZ dairy industry is forecast to benefit from continued growth and productivity for many years to come. Cheese production is one of the most complex in the dairy industry, involving a variety of processes to achieve the final product. Automating processes in cheese manufacture can improve a manufacturing plant’s productivity to meet increasing demand. Accurate control and customisation of manufacturing processes is necessary for optimal large-scale quality cheese production. Skilled engineers and technologists are required to designing manufacturing processes to produce consistent product characteristics that meet customers’ expectations. Advances in process and motion control technology have allowed processes that have historically been manually operated in a cheese manufacturing plant to be automated, improving efficiency and safety. When an international cheese manufacturer decided to automate its cheese slicing processes, it called on Cheese Solutions New Zealand Ltd (CSL), a leading New Zealand OEM machine builder, to design a system to meet its specific requirements. CSL utilised the design capabilities of long-standing system integration partner Integrated Automation Ltd (IAL) to develop a solution that would meet the manufacturer’s requirements. Recent advances in motion control technology take cheese slicing to a whole new level. The project requirement was to take an industrystandard block of cheese and slice it to specified dimensions and weight. When looking for products on the market that could achieve this, IAL decided to use the control processor capabilities of ControlLogix from Rockwell Automation. The challenge was to provide the customer with a complete cheeseslicing production line that could take a 20 kg block of cheese and pass it through a number of machines to break it down into smaller blocks which would then be sliced to form the end product: a slice of cheese measuring 90 x 90 x 2.5 mm. The solution lay in providing precise, highspeed synchronised motion control. An important part of this was accurate control of the portioning process to ensure the product was cut accurately with minimal wastage. According to Stephen Cotter, Solutions Architect - Motion Control, Rockwell Automation, “While the rest of this plant utilises product solutions from Rockwell Automation, this new machine required additional motion
control capabilities.” The new L73 processor, which has faster processing capabilities and improved motion control, was used. “It’s certainly the processor for the job because it’s up to speed to control the motion at the cheese-slicing business side,” continued Cotter. The application depends on precise motion control and timing. The block of cheese has to be indexed precisely because the slicing is performed with a rotating knife. Movement of the cheese and rotating blade needs to be coordinated as the speed at which the cheese must move is dependent on the density, weight and size of slice required. To achieve this, ControlLogix required a sample code with a particular CAM profile that the Rockwell Automation OEM team developed in Singapore. ControlLogix provided the single control platform with © iStockphoto.com/photovideostock RSLogix5000 design and configuration software. “In addition to the advanced control capabilities required, building this machine also required a comprehensive mechanical design to ensure the machine’s mechatronic system is reliable enough to carry out the tasks of slicing the product,” said Donovan Ryan, Director, IAL. “There was no other choice but to go with the new L73 processor in this high-speed motion application; every millisecond was critical.” Safety was also a consideration. The mechanical design of the cheeseslicing machine ensures the rotating blade was protected from operator access at all times. Maintenance requirements were minimal as the engineers were already familiar with the Logix technology. The cheese slicer provides the manufacturer with the flexibility to adjust the cheese’s thickness automatically. By checking the weight, the thickness of the slice can be adjusted by changing the CAM profile to account for the density of the cheese. “This solution provides the customer with the ability to accurately perform to the required velocity with the ease of integration using RSLogix5000 motion control commands,” said Cotter. As consumer demand increases, automation and process technology help improve productivity in the cheese industry. The benefits of automating the cheese manufacturing plant extend beyond the amount of product on the supermarket shelf. Establishing clean, efficient and automated processes minimises wastage of natural resources while providing industry with a way to meet increasing customer demands for quality dairy products.
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FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33
Rockwell Automation Australia Contact info and more items like this at wf.net.au/S217
INSTRUMENTATION & SENSORS PRODUCTS
ULTRASONIC SLUDGE MEASUREMENT The Hach Sonatax sc with sc200 controller is designed to help with sludge extraction and the management of recirculation, and provide warnings of potential solids washouts or process upsets by continuously measuring the sludge blanket level. Its digitised probe eliminates interference and features a quick LED system check. If connected with the sc1000 controller, graphical display of sludge profile is also available. The Sonatax sc offers reduced maintenance with an innovative wiper design, and a built-in position sensor can be used to resume measurements after skimmer passes. The same sensor can also compensate for angle when the probe is not mounted exactly vertically. High accuracy is achieved by automatically scanning a range of frequencies to find the ideal settings for the solids concentration for the application. Built-in software disregards signals reflected from tank structures such as pipes and rods. Automatic temperature compensation ensures the ultrasonic measurement is unaffected by seasonal changes in water temperature, making seasonal calibration unnecessary. A visual performance LED indicator light on the probe provides quick glance assurance of proper performance. Troubleshooting, particularly in applications with multiple sludge blanket level probes connected to one controller, is quick and easy. Hach Company Contact info and more items like this at wf.net.au/S269
OVAL GEAR FLOWMETERS Dimak provides a range of oval gear positive displacement flowmeters which provide high levels of accuracy and repeatability for a wide range of most clean liquids irrespective of viscosity and conductivity, including fuel oils, additives, chemicals, food bases, paints, viscous emulsions, insecticides, alcohol and solvents, either pumped or gravity-fed. The oval gear flowmeters come in sizes from 4 to 100 mm in aluminium, stainless steel and ductile iron for flow ranges from 0.04 L/h to 1500 L/m. The range offers modular process connections and there is no requirement for flow conditioning. They have bi-directional flow capability and a wide turndown, and all-metal rotors give high stability. Dual outputs (reed and Hall effect) are standard, as well as a hyperpulse highresolution pulse output, with optional quadrature pulse output. Hazardous area versions are also available. Trimec Flow Products Pty Ltd Contact info and more items like this at wf.net.au/S018
34 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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INSTRUMENTATION & SENSORS PRODUCTS
DIFFERENTIAL PRESSURE INSTRUMENTS Emerson Process Management has introduced a significant number of enhancements to its Rosemount 3051 pressure instruments. The first of the enhanced capabilities is a standard reference accuracy of ±0.04% of span down to a 10:1 turndown. This improvement drives the total performance in typical operating conditions to ±0.12% of span. The Power Advisory Diagnostics feature is a predictive diagnostic tool that allows users to identify electrical loop issues, at the instrument or anywhere in the loop, before they cause a loss of measurement. With simple three-step activation and guided troubleshooting, users of all experience levels can easily implement this diagnostic to help prevent costly outages and minimise the time spent diagnosing and resolving the root cause of a measurement issue. The company has added a local operator interface (LOI) to the product, designed with straightforward menus and both internal and external configuration buttons for on-the-spot commissioning - even in hazardous areas. The enhanced instrument also offers selectable HART revision capability (HART5 and HART7) to deliver the latest features to those that are ready to take advantage of the latest HART revision while ensuring seamless integration with any installed host, asset management system or configuration tool. The product now also offers SIL2 certification, allowing users to avoid extra shutdowns for safety testing. Emerson also provides full documentation for efficient SIS compliance. Users can add Power Advisory Diagnostics to SIL2certified transmitters to improve safety throughout their entire electrical loop. Emerson Process Management Contact info and more items like this at wf.net.au/S388
MAGNETIC FLOWMETERS Yokogawa has enhanced the ADMAG AXR two-wire magnetic flowmeter. This enhanced flowmeter has been certified for use in safety integrity level 2 (SIL2) applications and it supports the latest HART 7 protocol, eliminating the need for convertors to connect with HART-compliant control systems. HART 7 also supports and automatic alarms when the device’s settings are modified or a problem is detected by self-diagnostics. The ADMAG AXR flowmeter uses a dual-frequency excitation method, with low-frequency excitation that ensures stable measurement of flow rates and high-frequency excitation that delivers high noise resistance, thus realising stable measurement in a wide range of fluid conditions. This high-performance two-wire flowmeter can be used in both monitoring and control applications. Its installation and maintenance costs are significantly lower because two-wire magnetic flowmeters do not require a dedicated power supply unit and use only a single pair of cables. Their low power consumption also reduces running costs. In addition, explosionproof types suitable for installation in hazardous areas are now available for the entire range, covering bore diameters from 25 to 200 mm. Yokogawa Australia Pty Ltd Contact info and more items like this at wf.net.au/R549
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FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 35
NEW PRODUCTS
SAFETY CONTROLLER The Pilz PNOZ m B0 is an updated base unit for the PNOZmulti configurable control system. The base unit has the ability to be expanded on the right-hand side with I/O modules, which can be used as both inputs and outputs. Users benefit from increased flexibility in engineering. At a width of 45 mm, the base unit saves space in the control cabinet and also provides an integrated, illuminated display with individually customised texts, enabling rapid commissioning as well as diagnostics. The resulting PNOZmulti 2 control system can be used for safety and standard applications in all engineering sectors. The base unit has a total of 20 safe inputs, up to eight of which can be configured as standard outputs. Also available are four safe semiconductor outputs and four safe test pulse outputs, up to four of which can be configured as standard outputs. Fewer unit types are needed as a result,
enabling hardware and storage costs to be minimised. The base unit can be expanded with a maximum of two I/O modules. These provide a total of 16 inputs and 8 semiconductor outputs. The new configurable control system is suitable for applications up to and including SIL CL 3 and PL e. Pilz Australia Industrial Automation LP Contact info and more items like this at wf.net.au/S408
ETHERNET RADIO MODEMS Weidm端ller has released its WL Series of long-haul ethernet radio modems. Designed specifically for industrial use, the rugged and robust, upright WL units have a very narrow footprint. At 40 mm wide, the units provide user convenience while saving on space to help users build networks quickly and efficiently. The series incorporates a range of models including a 2.4 GHz, 5 GHz and 900 MHz option. The high-throughput modems provide connectivity for line-of-sight distances from 5 up to 20 km. All models have an in-built routing function and blacklist/whitelist for controlling traffic. A built-in signal strength tester measures both bandwidth and the signal strength between two radios. In addition, all units include dual diversity antenna connections and a choice of different antenna accessories to help customise the installation. The WL Series provides remote wireless I/O mapping where up to 31 I/O units can be daisy-chained to a transceiver at each end. A selection can be made between digital, analog and combinational input and output types of I/O units. The 2.4 GHz model can be set up in a mesh network topology providing redundancy and greater reliability. Each transceiver also has a built-in conversion for serial Modbus RTU to Modbus TCP. DIN rail-mounted and operating from 10-30 VDC supply, the plug-and-play WL models provide easy configuration through a built-in web interface and feature LED status indicators. Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/S208
36 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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NEW PRODUCTS
INFRARED TEMPERATURE SENSOR The PyroMini infrared pyrometer from Calex Electronics has a miniature sensing head measuring 18 x 45 mm, making it suitable for mounting in tight spaces. The high ambient sensing head is capable of withstanding temperatures of up to 180°C without water or air cooling and has a measuring range of -20 to 1000°C. Manufactured from 316 stainless steel and sealed to IP65, the PyroMini sensing head is suitable for the food and pharmaceutical industry, as well as automotive manufacture and many other industrial measurement and control applications. The non-contact temperature sensing head utilises a low-noise interconnecting cable (available in lengths from 1 to 30 m), making it resistant to interference from external electromagnetic fields such as those encountered with dynamic moving machines like robot arms. The backlit touch-screen interface provides a large, bright display of the measured temperature in digital format as well as in a graphical view that shows the history of the measured temperature, date and time. In alarm conditions, the display changes colour to provide an immediate and obvious alarm indication. When in data logging mode, the PyroMini records the temperature related data to a MicroSD card. With a 2 GB MicroSD card, the user can store 28.4 million time and date stamped readings, which provides almost one year’s worth of data at the fastest possible sample rate of one per second. Output options include an analog 4-20 mA temperature-related retransmission, as well as RS485 Modbus and two alarm relay outputs. Heastern Industries Contact info and more items like this at wf.net.au/R779
INTEGRATED SERVO DRIVE MOTOR The Allen-Bradley Kinetix 6000M integrated drive motor combines servo drive and motor technologies in a compact, on-machine package, using the MP-Series food-grade servo motor and Kinetix 6000 multi-axis servo drive technologies. Moving servo drives out of the control enclosure and onto the machine delivers significant space savings, while reducing cabling. The integrated drive-motor system is claimed to reduce panel space required by up to 60% for a typical 8-axis system. Additionally, the number of cables exiting the control enclosure is reduced by as much as 75% because a hybrid/network cable daisy chain replaces the individual power and feedback cables. The drive-motor is designed to integrate seamlessly with the Kinetix 6000 and Kinetix 6200 multi-axis servo-drive systems and features an integrated drive-motor power interface module that mounts directly to a standard Kinetix 6000 power rail. The mounting flange and shaft dimensions of the integrated drive-motor units are identical to the MP-Series motors of the same frame size, minimising the mechanical changes needed to use integrated drive-motor technology. The system is suitable for applications such as packaging, converting, print and web machines. It meets the needs of food and beverage packaging and handling applications by offering features geared for the industry, including enhanced sealing techniques, corrosion-resistant materials and coating appropriate for food environments. The drive motor is available in three different frame sizes, offering optional holding breaks and SIL2/PLd safe torque-off functionality. Rockwell Automation Australia Contact info and more items like this at wf.net.au/S049
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FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 37
AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA
BECOME AN ENGINEERING ENTREPRENEUR TODAY
A
lmost on a daily basis, you read about Australian manufacturing (and even mining) businesses shutting down. After the hammering of the recent ‘Great Recession’, companies are rapidly reducing tangible assets - buildings, machines and, inevitably, people such as high-cost engineering staff. And we know that there is a massive amount of outsourcing going on - meaning jobs go elsewhere, often overseas. This is all happening today and will eventually impact on you in some form. The days of expecting a job for 30 to 40 years, say, from one company are rapidly diminishing as competition intensifies. I clearly remember starting out in the diamond mining business as a junior engineer with thousands of other highly skilled engineering professionals working for this one company. It had been around for over a hundred years and we all believed it would be around for many more years. Today, it is a poor shadow of itself with only a tiny number of engineers and technicians. An unbelievable situation when one considers how dynamic and profitable it was only 20 years ago. We thus need to approach the problem of employment from a different angle and create engineering jobs ourselves. And employ others. Engineering professionals have the innate technical prowess to make things. Add in creativity to the mix and an understanding of what the market wants and you could have a winning product or service within months. Admittedly, you may work long hours and be exposed to some stress along the way. But the winners are individuals which we refer to as engineer-entrepreneurs and companies that come up with new products and services which the global community wants. And keep coming up with new products or improvements to existing products. Otherwise they also die. We thus need the engineer-entrepreneur to conceptualise and design new products and services. A product doesn’t have to be something totally unique or new; a slight improvement on an existing product, service or process can also be a winner. This ap-
plies to you whether you are working for another company or for yourself. Seek out opportunities to innovate and create new products and services. In this way you can extend the life of your company and your career. It should be noted that as an engineerentrepreneur, there is a chasm between successfully operating a startup company and a small business. The much vaunted business schools tend to gloss over the differences and treat both as the same, but they are totally different. One key difference is that a startup company often has a brilliant product which has incredible possibilities, but no actual market (at present) - so the startup has the additional challenge of getting the product to market. Engineering professionals also have to be ferociously self-sufficient, self-sustaining and lifelong learners responsible for staying in business. They also have to be prepared to learn from their customers in optimising their creations so that they are economically viable. Often we hear things from our customers that we don’t want to hear. Inevitably, engineer-entrepeneurs must be prepared to have a high threshold of tolerance to repeated failure and the ability to persist to success. Above all - you have to believe in yourself. As George Lois points out: Creativity can solve almost any problem. The creative act, the defeat of habit by originality, overcomes everything.
S t e v e M a c k a y, Ph D C PEn g , h a s wo r k e d mainly in the industrial automation and data communications fields for the past 30 years and is currently dean o f e n g i n ee r i n g w i t h worldwide engineering education business IDC Technologies (www.idc-online.com). He has also published over 30 engineering books, as both editor and co-author.
38 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013
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List (A) Job Function 1 Management - Corporate/General 2 Management - Manufacturing/ Engineering/Specialist 3 Engineer - Electrical 4 Engineer - Electronics 5 Engineer - Process 6 Engineer - Project 7 Purchasing/Procurement 8 Technician - Maintenance/Service 9 Technician - IT 10 Technical Officer 11 Scientific Officer - R&D 12 Scientific Officer - QA 13 Consultant 14 Contractor/Tradesperson 15 OHS/EHS 16 Education/Training 17 Student-Undergraduate/Apprentice 18 Analyst 19 Sales/Marketing
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