What’s New in Process Technology Nov 2013

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ON THE COVER

1113 WHAT'S NEW IN PROCESS TECHNOLOGY NOVEMBER 2013

The Fluke VT04 is the most powerful addition to the groundbreaking Fluke Visual IR Thermometer family. The VT04 features PyroBlend Plus technology that delivers 4x sharper images for enhanced problem detection,

CONTENTS 6

Migrating legacy control systems

Making sure the benefits outweigh the costs

10

Hot products online

13

New products

Fluke Visual IR Thermometers are point-and-

22

Personal gas detectors

shoot devices that are specifically designed

Why two sensors are safer than one

34

Numerical simulation

Enabling continuous manufacturing in the pharmaceutical industry

ity to make reports with included SmartView

42

As I see it

reporting software.

Industry is doing it tough

best-in-class field of view for tight spaces and powerful automatic monitoring features that detect stubborn, intermittent issues.

Every Fluke Visual IR Thermometer has a built-in digital camera with thermal heat map overlay to instantly identify the exact location of the problem.

to require no training. With just one button, the VT04 Visual IR Thermometer simultaneously saves a digital image with a thermal heat map overlay instantly giving users the exact location of the problem and the abil-

It’s a frontline troubleshooting tool designed to fit in the user’s pocket. Less than half the size of infrared cameras, Fluke Visual IR Thermometers feature true slimline pocketsize design.

The Fluke VT04 also has three powerful alarms and automated monitoring features that take images at a set duration or when a temperature alarm has been triggered. This is ideal for unattended monitoring, comparing machinery over time and troubleshooting stubborn intermittent issues. Take advantage of Fluke’s current cash rebate promotion on the VT04 – available for a limited time.

Fluke Australia Pty Ltd www.fluke.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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MIGRATING LEGACY CONTROL SYSTEMS

MAKING SURE THE BENEFITS OUTWEIGH THE COSTS Glenn Johnson, Editor

© iStockphoto.com/hh5800

Control system performance can have a significant impact on a plant’s bottom line, and recent years have seen the emergence of new technologies that can greatly assist in further improving plant efficiency, performance, safety and business integration. But taking advantage of these new technologies will, in many cases, mean upgrading the existing DCS infrastructure.

6 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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L

egacy distributed control systems (DCSs) often cannot meet presentday objectives of providing business information sharing, improved asset management and maintenance, lower energy consumption and better product quality, so many plant operators are considering migrating to a new DCS. However, before this can take place, there needs to be a financial and economic justification for doing so. The justification needs to compare the total cost of operation with the existing DCS, with the costs and benefits of a more modern system.

For plant managers, there needs to be sufficient grounds to go to the trouble and cost of replacing a working DCS. Maintenance and the availability of spare parts are always significant considerations in a migration decision - components may be reaching the end of their useful life or failing excessively, and it may be becoming difficult or expensive to find replacement parts. It can also become more difficult over time to find personnel qualified to troubleshoot and repair older equipment and systems, especially as existing plant workers reach retirement age.

Excessive failure rates, difficulty in finding spare parts and lack of qualified expertise can all add up to increased downtime - a significant problem for any process plant.

Then there is the performance of the older DCS - it may not be living up to the requirements of today’s standards of quality and energy efficiency. Newer systems allow more processes to be automated, enabling tighter control of existing processes and introducing new control capabilities that improve asset management, compliance and energy monitoring, as well as health and safety.

Most plants will have specific main motivations for migrating or replacing a DCS. Generally the motivations will include: • Obsolescence - the high cost of maintaining older equipment • End-of-life - the cost of replacing older equipment due to corrosion or age • Futureproofing - locking in vendor support for a longer period • Upgrading or replacing - modernising equipment for better performance or new capabilities • Capacity - current systems are nearing their load capacity • Improved UI - improving operator performance through better tools, alarm management and reporting • Cost reduction - improving performance and lowering footprint • New features - improved alarm management, operator effectiveness and asset management

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• Multivendor support - being able to use ‘best-of-breed’ equipment that may not be possible with older proprietary systems • Process data at the business level - improving decision-making and creating business agility • Security - providing better integrated capabilities while reducing security risk Migrating a DCS is going to represent significant cost to the business, so any plan to replace a system must provide an improved business value proposition - lower installed cost, lower life cycle cost and the ability to take advantage of new opportunities for improvement.

Risk and reward The risk of failure grows exponentially as equipment ages - and the DCS is no exception. Compound this with the reduction in the availability of support, spares and expertise over time, and leaving a legacy DCS in place for too long may become a risk too great.

One question that needs to be asked is: what am I missing out on by continuing to support an outdated control system? Improvements in process performance, operator effectiveness, downtime and maintenance can all be limited by staying with an outdated DCS, but a well-planned and -executed migration to the latest technology provides opportunities for improvement in all these areas.

Modern DCS technology also supports the latest in networking and wireless systems, expanding the reach of the control system into areas that could not be accessed by the legacy system. Essential asset monitoring (EAM), energy conservation measures (ECM) and health, safety and environment (HS&E) capabilities can now all be integrated and supported with a modern DCS.

Have a vision The fact is a new DCS will offer new opportunities, so the justification for a migration will be helped along if you have a vision of where the plant could be if those new opportunities can be taken advantage of. Take stock of the capabilities of the current system and determine where its weaknesses and inefficiencies are, then compare that with the improvements available to existing processes that might be possible by upgrading.

Then consider the additional opportunities that newer technology presents. Can the current system be expanded at low cost through wireless technologies, enabling new forms of monitoring such as EAM, ECM and HS&E? Can the current system effectively integrate with business systems to provide

NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

Control systems

MAC/Digital Plant Project Cost Breakdown Curve

Profit

Superior Manageability

Faster Start-up

Traditional Start-up

Cost

Time Reduced Capital Spend

Increased Profit Traditional Project Cost Breakdown Curve

Faster Profitability

Capital Cost Savings

the information the business needs to make informed decisions?

It helps to have a vision of where the plant control system might be in the next few years and the benefits a migration will provide to your organisation.

Explain your vision The initial step is to get buy-in from the plant management that will approve the project. The opportunity to improve process performance, plant reliability, maintenance, energy consumption and HS&E by modernising should be explained to the plant management, maintenance manager, reliability engineer, HS&E officer and project/turnaround manager.

Investment in a new DCS can be justified on the basis of improved efficiencies and reduced downtime, as well as the potential for lower maintenance cost, lower energy consumption and improved HS&E, through the new technical opportunities presented by newer technology.

Migration strategy A well-planned and -implemented DCS migration should enable your organisation to migrate the legacy platform at your own pace, allowing new equipment and software to be easily integrated with the old system. A structured approach will allow the system to be migrated subsystem-by-subsystem, minimising downtime and impact on day-to-day operations, and minimising those elements of the migration that will require downtime.

FEED is the key The key to a successful migration involves effective front end engineering design (FEED), driving the bulk of the migration planning into the initial stages of the project. To derive the true business benefit of a new technology, proper planning must take place. As well as proposing a design and migration strategy, the FEED should be able to provide a rela-

tively accurate estimate of business benefit and costs (within 10%), including a detailed functional scope, a detailed project execution plan and a detailed procurement plan. Having a well-defined scope will provide a more accurate estimate, lower contingency and lower overall project costs.

The FEED can also include the required economic justification, including the expected process and business returns on investment.

The effort and upfront cost of the FEED can deliver major financial benefits because it is work that would otherwise be done in the first 10-25% of the project and helps reduce the risk of problems later on in the project, by providing early identification of problem areas and changes that need to be made to resolve them.

Zero downtime migration Because of its cost to the business, downtime should be reduced to as close to zero as possible.

The money saved by keeping downtime as low as possible is significant, whether it is during a scheduled maintenance outage or during an outage specifically planned for DCS cutover, but of course the ideal situation is to achieve a hot cutover, in which the new system seamlessly takes over from the old system with no need for process interruptions.

Hot cutover, however, does need careful planning and sequencing. For example, simple loops such as indication-only measurements can be cut over first, enabling the team to adapt to the new system in a low-risk environment. Migrating one loop at a time makes hot cutovers more manageable than commissioning an entire unit after a shutdown or turnaround, and minimising shutdown periods for critical instruments and safety systems reduces costs.

Effective communication is also important, so that all personnel are aware of

8 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

work being performed, and so that safe procedures are followed at all times.

Hot cutover does not make sense in all situations, and migration during scheduled turnarounds is more common in practice.

Preserving valuable assets It should be remembered that not all parts of a legacy DCS need to be replaced, and so, when assessing suppliers, find one with the flexibility to offer solutions that allow you to preserve assets worth keeping. The embedded knowledge in these systems, accrued over the system lifetime, have ensured that your system has performed the fundamental job it was purchased to do. Any new system to be implemented must offer a compelling value proposition over the old system. It should also preserve the intellectual capital of the old system to the degree that it makes sense to do so.

Use an experienced partner Key to the success of a DCS migration is not just the choice of system, but in partnering with an organisation with experience and understanding of the complete migration process, and that can demonstrate effective, proven migration strategies. As end-user organisations are facing an ever-reducing experience base in-house, and an increasing range of responsibilities, it is important that the partner organisation is able to provide a complete array of services to assist the migration process.

Your chosen partner should be able to provide a full suite of services, from consulting services and FEED, to project implementation, after-sales service and training. Look for a supplier with strong experience, not only in its DCS product, but also in field instrumentation, control valves, fieldbus, networking and wireless implementation.

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HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

>

RUGGED DAQ SYSTEM

The NI cDAQ-9188XT is a rugged, 8-slot ethernet chassis that is designed for distributed or remote measurements in extreme environments.

National Instruments Australia

WF.NET.AU/U862

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The PSR-URM4L contact extension device allows users to efficiently process safetyrelated OSSD signals of a light grid as floating contacts.

Phoenix Contact Pty Ltd

WF.NET.AU/V342

>

SAFETY LIGHT GRID CONTACT EXTENSION

DRY BLOCK TEMPERATURE CALIBRATOR The Fluke 9141-NATA dry block temperature calibrator has been designed with ease of use and functionality in mind.

TechRentals

WF.NET.AU/V405

> SAFETY GATE LOCK RANGE Pilz has released new versions and accessories for its PSENslock safety gate range.

Pilz Australia Industrial Automation LP

WF.NET.AU/V175

10 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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Make the unpredictable totally predictable.

© 2012 Swagelok Company

Swagelok® Pressure Regulators are now an even better choice for all your pressure regulator needs. Why? Well, alongside our proven experience and expertise, our range now covers sizes from 1/8 to 4 in. and all your regulator needs – high-flow capability, two-stage, back-pressure and vaporizing models. With our regulators you get accuracy, sensitivity and pressure stability. In short– total predictability. Exactly what you would expect.

Visit swagelok.com/pressure.

CASE STUDY

Boral’s Peppertree Quarry achieves an industry-leading mobile crushing solution

Due to the anticipated depletion of raw material reserves at the 100-year-old Penrith Lakes Scheme in Sydney, of which Boral is a major shareholder, it has been necessary to find a new source of materials to address the needs of Sydney’s construction industry into the future.

As part of Boral’s Sydney Aggregates Project, Boral has implemented an innovative in-pit crushing solution at its new Peppertree quarry, situated at Marulan South in the NSW Southern Tablelands, around 180 km south-west of Sydney.

Due to become fully operational in 2014, the new quarry will supply the Sydney metropolitan area and greater NSW building and construction industries with up to 3.5 million tonnes of aggregate products per annum.

In addition to the Peppertree quarry, the $200 million Sydney Aggregates Project includes new rail infrastructure in and around the quarry, a new manufactured sand plant at Boral Cement in South Marulan and a new rail transfer terminal at the Boral Maldon Cement Works near Picton, NSW. “Boral is now looking to optimise its quarrying process and get away from the traditional load and haul methodology where you have a large number of trucks and people moving between the blast site and the fixed crushing plant,” said Boral Site Manager Steve Parsons.

Rigorous research into finding a crusher that could handle the planned production volume at the Peppertree plant led Boral to select Metso’s Lokotrack LT160 together with the company’s patented Lokolink mobile conveyor system.

The Lokotrack LT160 at Peppertree is the largest mobile crusher in the Southern Hemisphere, weighing in at 285 tonnes and measuring 12 m high by 25 m in length. Extensive design consultation between Boral’s technical staff and Metso’s design team prior to design finalisation and manufacture has produced a machine with a number of innovations not seen on a mobile machine before.

In a conventional crushing plant, a drill and blast team blast the shot and develop a muck pile. A front-end loader at the muck pile loads haul trucks which transport the rock to a fixed primary crusher.

With the in-pit crushing solution at Peppertree, an excavator located on the muck pile loads material directly into the Lokotrack’s hopper.

The rock moves along a grizzly feeder that passes undersized rock directly onto the machine’s outbound conveyor. Only the large rock that needs to be crushed passes through the jaw crusher, which is capable of processing rocks up to one metre in size. In this way, energy isn’t wasted on passing small material through the crusher.

Crushed rock is then transported to the fixed, in-pit belt conveyor via two mobile Lokolink conveyors. The fixed conveyor carries crushed rock from the Lokotrack to the fixed plant for further processing. A patented swivel mechanism on the Lokolink conveyors ensures crushed material flows freely at all conveyor angles.

The Lokotrack LT160 can crush 1150 tonnes of rock per hour and needs to be relocated every few hours - a process which can be done in minutes by an operator via a remote console worn around the operator’s waist. The Lokotrack is moved to the next loading position and the unique technology of the Lokolink conveyors allows them to simply follow.

12 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

When blasting is performed, the Lokotrack and Lokolink conveyors move to a safe distance around 70 m away. When the time comes to move to a different pit location, the Lokolink conveyors are disconnected from the field hopper using hydraulic actuators. The Lokotrack and Lokolink conveyors can also move from one level to another along a normal ramp.

The LT160 is a fully self-contained electrical machine. The trackmounted drive of the machine is hydraulic while the grizzly feeder and the 200 kW crusher motor are driven electrically so there is no environmental impact from diesel fumes. However, in case electrical power is unavailable the machine has a reliable, onboard CAT diesel generator which can be used to run the Lokotrack’s hydraulic system and Lokolink conveyors.

After the machine was delivered to the Peppertree site in late 2012, the LT160 went through a three-stage commissioning process (static, dry and wet) and achieved practical completion in the middle of August this year.

According to David Bolton, Sydney Aggregates Project executive manager, “One of the key learnings for Boral from this project is that when importing plant and equipment there are a number of opportunities to adjust the design and capability of the equipment.

These opportunities are rarely taken up by Australian industry. We’ve found that the need to partner with offshore suppliers is critical and it’s achievable.”

While there were challenges with adapting the LT160 to Boral’s rigorous standards, Parsons said the project ran extremely well due to Metso’s commitment as well as the trust and rapport between the Metso and Boral teams. “The whole thing worked very well. It was the understanding of what was required and the ability of both teams to communicate seamlessly that delivered the result. It’s the perfect template for a project.”

Metso Minerals (Australia) Limited A longer and more detailed version of this article can be read online at wf.net.au/V422.

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NEW PRODUCTS

HIGH-CURRENT CONTACT INSERTS The Heavycon-B and Heavycon-HV contact inserts are now available with Phoenix Contact’s push-in connector technology.

The B-series includes pin and socket inserts with 6, 10, 16 or 24 pins for 500 V and 16 A. High-voltage inserts with 3, 6 or 10 pins plus two delayed mating contacts

COMPACT AC DRIVES The Allen-Bradley PowerFlex 523 AC drive is designed to be suitable for builders

for 830 V and 16 A are also available.

of simple, stand-alone machines, balancing the need for ‘just enough’ control with a design that lowers total costs to design, develop and deliver machines.

Machine builders can use a standard USB connection for managing drive configuration files. They can also program the drive through its built-in human interface module (HIM), which displays data on the drive’s LCD with scrolling QuickView text and detailed explanations of parameters and other codes. AppView and CustomView tools help speed-up configuration by providing groups of parameters for common applications and by allowing users to save their settings to new parameter groups.

An optional dual port EtherNet/IP adapter supports ring topologies and provides device level ring (DLR) functionality, which can help provide network resiliency and improve machine availability. Adding a dual port EtherNet/IP adapter to a PowerFlex 523 AC drive also provides automatic device configuration, which saves time by automatically downloading configuration files when a drive is replaced.

The AC drive has a power range of 0.2-11 kW and motor control options including volts-per-hertz, sensorless vector control and Economizer mode in sensorless vector control.

The AC drive requires 50 mm of clearance on the top and bottom when installing into a cabinet. It is rated up to 50°C, and with an optional control module fan kit, the drive can withstand temperatures up to 70°C with current derating.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/V335

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Rigid and flexible conductors with end sleeves of up to 2.5 mm² can be easily plugged directly into the inserts.

The orange pusher provides a defined, safe-to-use opening mechanism used to release the connection. It can be triggered even when installed on the inside of a control cabinet. The HC-CP red plug coding from Phoenix Contact has been included to prevent incorrect connections.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/V009

NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

NEW PRODUCTS

MOTOR CONTROL CENTRE ABB has launched a range of SafeStart lowvoltage motor control centre (MCC) technology.

The SafeStart range improves safety, equipment reliability and ease of maintenance for operators

SIMULATION SOFTWARE MathWorks has announced Release 2013b (R2013b) of its MATLAB and Simulink product families, focusing on increased systems integration and compatibility with its latest range of updates. Release 2013b sees MATLAB and Simulink gain greater integration with increasingly common hardware platforms like 64-bit processors and the Arduino open-source platform.

The latest range of updates will also significantly enhance MATLAB’s programming capabilities, including greater support for unstructured data types and C/C++ code generation. A range of MATLAB toolboxes will also receive new features including SPI-based communication with integrated circuits for statistical modelling; and a native ODBC driver to improve access speeds for instrument control.

R2013b is available immediately. More information is available at: http://www. mathworks.com.au/products/new_products/latest_features.html.

MathWorks Australia Contact info and more items like this at wf.net.au/V187

of demountable-type MCCs in the mining and minerals industry.

To address the key needs of operators and owners of local mine sites, the design of the SafeStart MCC has been engineered and developed in Australia based on direct feedback received from a series of market surveys conducted by ABB in Australia.

The SafeStart MCC modules are designed to improve safety for operators and electrical maintenance workers with improved protection against arc faults and with interlocking mechanisms. This allows the main switch handle to be padlocked in the OFF position with the door open or closed, and also prevents insertion or withdrawal of the demountable module when the main switch is in the ON position.

SafeStart low-voltage MCCs have been designed to operate in harsh conditions such as operation ambient temperatures of between -5 and 50°C, and dusty environments which demand protection ratings of up to IP54. Temperature rise tests and internal arcing fault tests have been conducted under the worst conditions of IP54 without extrapolation or assumptions.

Maintenance has also been simplified due to modular design. All demountable modules come in standard sizes and are provided with facilities to allow for quick interchange or replacement of modules within the framework. Main busbars are of a maintenance-free construction and distribution bars are fully phase-segregated, reducing the probability of an arc flash.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/V292

ELECTRICAL ENERGY LOGGER The Fluke 1730 three-phase energy logger is claimed to be an intuitive, easy-to-use tool with professional-level, energy data-gathering capabilities.

Detecting electrical waste normally requires logging energy consumption over time, using expensive power-quality analysers operated by engineers with advanced training.

The Fluke 1730 energy logger offers a straightforward, intuitive design that lets technicians load studies and energy logging right out of the box. The results provide facility managers with the information necessary to identify and prioritise energy saving projects.

The compact energy logger conducts key measurements of voltage, current, power and power factor to identify areas of energy waste. All measured values are logged automatically and can be reviewed during logging. Common set-up errors are rectified, through re-engineered cables, digital check and auto-correct of all connections and an on-screen wizard for interval set-up. It has a high safety rating (600 V CAT IV/1000 V CAT III), can be powered directly from the measured circuit eliminating the need to find a power outlet, and has two USB ports for fast data downloads to PCs or standard thumb drives.

Data logged by the device can be imported into the the company’s Energy Analyse software for further processing and archiving. The software lets users analyse energy or load profiles including zoom in and zoom out on details, add comments, pictures and other information to data, overlay different logging sessions, create reports and export measurement results.

Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/V193

14 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 15

NEW PRODUCTS

UNIVERSAL SURGE ARRESTORS BLITZDUCTOR XTU arresters are combined lightning and surge arresters for protecting information technology and automation systems. They are different to other arrestors because the nominal voltage is not specified, but instead can be used for all voltages from 0 to 180 VDC. Each BLITZDUCTOR XTU uses technology which allows the arrester to automatically detect the signal voltage and adapt its voltage protection level to the currently applied signal voltage, making them suitable for many applications.

In case of lightning or transient surges, BLITZDUCTOR XTU arrestors always provide a minimal residual protection voltage for every signal input voltage and therefore afford maximum protection for systems and connected devices.

BLITZDUCTOR XTU arresters are also suitable for retrofitting existing systems with surge protective devices, or replacing existing arresters where it is uncertain which nominal voltage is to be used.

No programming or set-up is required. Each BLITZDUCTOR XTU consists of a BXTU protection module, containing all the surge protection components, and a DIN rail-mountable BXT base. The base features terminals for two twisted pairs of wires and an earth connection. A switch contact allows the protection modules to be removed and inserted without interrupting system operation.

BLITZDUCTOR XTU arresters feature the LifeCheck monitoring function, which allows for easy testing of arresters during operation. This monitoring function detects any arrester that is damaged, allowing for easy replacement and full protection of devices and systems.

DEHN + SOHNE GmbH + Co KG Contact info and more items like this at wf.net.au/U683

GAS-SPECIFIC GRAVITY METER The Micro Motion 3098 gas-specific gravity meter directly measures gas molecular weight and can be configured to output hydrogen purity, specific gravity, relative density, calorific value/BTU or Wobbe Index. Building upon Ni-span-C cylinder technology, this precision measurement technology provides the benefits of low cost of ownership, reduced maintenance costs and an integral transmitter. It is designed to help solve the problems that users confront on a daily basis, such as managing rapidly changing fired heater air-to-fuel ratios, reducing refinery hydrogen impurities and minimising windage losses in hydrogen-cooled generator sets.

The specific gravity meter incorporates a head-mounted transmitter that has the flexibility to digitally connect to distributed control systems as well as the ability to output raw sensor signals to flow computers - conforming to custody transfer best practices. The transmitter module has the capability of being able to output sensor data in four formats simultaneously: sensor frequency (time period), 4-20 mA, HART and RS485 Modbus. The gas-specific gravity meter incorporates a ‘known density verification’ diagnostic capability, which checks the meter for measurement alarm conditions, sensor integrity and the presence of coating, erosion or corrosion. This technology expands the availability of diagnostics information in critical density measurement applications and can result in significant reductions in maintenance costs and cycle times.

Emerson Process Management Contact info and more items like this at wf.net.au/V313

TEMPERATURE TRANSMITTER ifm efector has released a temperature transmitter with a display and IO-Link for food applications. The bright, 4-digit display offers optimum readability in addition to a fast response time. It is available in various probe lengths from 30 to 150 mm.

The integrated clamp and G1/2″ process adapters allow quick and easy installation. The transmitters of the TD series are supplied with a preset measuring range, so no complex configuration is required. For special applications the temperature range can be conveniently scaled via IO-Link.

In addition, these temperature transmitters are characterised by a compact and hygienic design with integrated adapters.

Protected to IP69K standards and featuring a fully welded highgrade stainless steel housing, the transmitters are designed to operate in particularly harsh applications. ifm efector pty ltd Contact info and more items like this at wf.net.au/V008

16 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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EXPERTISE In Hazardous Areas

Explosion Protection Equipment Pepperl+Fuchs, the world’s leading manufacturer of Intrinsic Safety, has acquired the Australian company GOVAN Industries. GOVAN has over 60 years’ experience in explosion protection technologies.

Utilising the updated manufacturing facility in Australia, Pepperl+Fuchs can now offer complete customised electrical protection equipment to the Australian and Asia Pacifi c markets, meeting both IECEx or ATEX standards.

Pepperl+Fuchs has a wealth of experience across the full spectrum of hazardous area protection technologies, from Ex i through Ex d including: Ex e Fieldbus Junction B oxes Ex e, Ex d Junction and Terminal Boxes Ex de, Ex d Local Control Units and Control Stations Ex d Flamproof Distribution and Control Panels Ex p Purge Solutions

Pepperl+Fuchs (Aust) Pty Ltd 131 - 149 Link Drive, Campbellfield Victoria 3061, Australia Telephone: +61 3 9358 3400 E-mail: pa-info@au.pepperl-fuchs.com Product Specific Information: www.govan.com.au Group Website: www.pepperl-fuchs.com.au

NEW PRODUCTS

ZIGSENSE CLOUD CONTROLLER The ZigSense Cloud Controller is designed to support internet-based SCADA applications where data from remote ZigSense wireless sensors is uploaded to a secured website. It is fully integrated with the ZigCloud online back-end management system to provide a complete system ready for use. To gain access from anywhere at any time, all that a user needs is a standard web browser, smartphone, tablet, laptop or PC. Once connected to ZigCloud there is need for SCADA, HMI or additional PCs. Data generated by sensors, both live and historic, is immediately available on the web browser. An authorised user can access multiple controller sites from a single online login session to monitor data and generate graphs, charts and reports. Multiple alarm thresholds can be

HMI DESIGN FOR MOBILE DEVICES

set for each monitored sensor. Alarm conditions may be set to gener-

Schneider Electric has announced its Vijeo Design’Air Plus

ate alert messages via email, SMS or voice calls, and local controller

feature in its existing Vijeo designer application for Android

actions can be programmed

and iOS tablets and smartphones.

to start or stop based on schedules, conditions or events, making the

The feature enables users to create a tablet/smartphone

ZigSense cloud controller act

project specifically for the tablet/smartphone display size.

like a PLC. In addition to direct

At run time, an operator can access the user application

interface to ZigSense

to display data and control automation processes on the

wireless sensors, the

tablet or smartphone.

cloud controller can

The Vijeo Designer’s drawing tools can be used to create

be interfaced to other

and edit a visual representation of the automation process.

Modbus ‘slave’ de-

Users can draw shapes and parts (such as rectangles,

vices or control its own

arcs and pies), toolchest parts (such as numeric displays,

local digital outputs

switches and bar graphs), use the gradient feature to

supporting energy us-

enhance the colour of the drawn objects, and set up an

age demand control

alarm panel for remote alarm monitoring.

strategy.

The feature provides operators with the capability to se-

Uploading sensors data can

lect a user application and, on successful login, download

be achieved via the built-in eth- ernet port or its optional built-in 3G

and launch a tablet/smartphone application. The operator

modem, or both. An optional built-in GPS modem and antenna makes

can view and monitor an automation process and, for

the cloud controller a solution for monitoring environmental conditions

example, change values in numeric displays and string

in mobile applications.

displays. In the alarm panel, the operator can monitor and

Conlab Pty Ltd

acknowledge alarms.

Contact info and more items like this at wf.net.au/V273

Schneider Electric (Aust) Pty Ltd Contact info and more items like this at wf.net.au/V192

M12-X CONNECTOR Weidmuller’s M12-X Cat 6A connector supports data transmission volumes up to 10 Gbps and meets the requirements of the latest Profinet Installation Guidelines for Cabling and Assembly as well as the demands of Category 6A. Purpose built to withstand high vibration, the M12-X type connector is suitable for use in the mining, rail, road and transportation industries. Rated to protection class IP65 and IP67, it is resistant to soiling and moisture. The unit features a full 360° metal shield connection point to ensure it is suitably robust for use in harsh industrial environments.

Created to deliver a long life and error-free connectivity, the connector’s pins are made from CuZn with a gold-plated contact surface. This assists the M12-X type connector in effectively withstanding up to 100 mating cycles.

The M12-X type connector is also designed for quick and easy field assembly, and does not require any special tools for installation. Plus, it can be operated in a broad temperature range, from -25 to +85°C. The connector is available as a standalone unit or with a moulded CAT7 cable in various lengths. The moulded cable ensures higher resilience, sturdiness and strength.

Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/V293

18 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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WE KNOW WE CARE WE CUSTOMISE FOR YOU…

E LE DRIV CTRIC MO ES T CONT & SOFT S ORS ROL & TA AUTO RTERS MATIO N

TOSHIBA INTERNATIONAL CORPORATION PTY LTD NSW Toshiba International Corporation Pty Ltd 2 Morton Street, Parramatta NSW 2150 Tel: (02) 9768 6600 Fax: (02) 9890 7546

QUEENSLAND Toshiba International Corporation Pty Ltd UNIT 4 / 20 Smallwood Place, Murarrie QLD 4172 Tel: (07) 3902 7888 Fax: (07) 3902 7878

VICTORIA Toshiba International Corporation Pty Ltd 411 Fern Tree Gully Road, Mt Waverley VIC 3149 Tel: (03) 8541 7960 Fax: (03) 8541 7970

NEWCASTLE Toshiba International Corporation Pty Ltd UNIT 1 / 18 Kinta Drive, Beresfield NSW 2322 Tel: (02) 4966 8124 Fax: (02) 4966 8147

MACKAY Toshiba International Corporation Pty Ltd 1st Floor 41 Wood St, Mackay QLD 4740 Tel: (07) 4953 4184 Fax: (07) 4951 4203

WESTERN AUSTRALIA Toshiba International Corporation Pty Ltd 10 Anderson Pl, Perth International Airport WA 6105 Tel: (08) 6272 5600 Fax: (08) 6272 5601

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NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 19

NEW PRODUCTS

EMBEDDED SYSTEM iBase Technology’s AMI311-970 fanless embedded system houses its MI970 Mini-ITX motherboard supporting thirdgeneration Intel Core processors.

The system functions as a desktop or wall-mount embedded computer system, with the front panel featuring LEDs for power and HDD, power buttons and two USB 2.0 ports. The rear panel features a serial port, DVI-I+DVI-D, dual USB 3.0+ ports, dual USB 2.0 and RJ45 ports, audio, a 2.5″ removable HDD tray and a PCI-E(x16) slots for graphics expansion capability.

The embedded system is equipped with 8 GB of DDR3 SO-DIMM system memory, a 320 GB hard disk drive and a 120 W power adapter.

Optional system memory and SSD storage upgrades are available. It is suitable for environments and applications where desktop space is at a premium such as factory automation, multimedia, medical and digital signage. The fanless compact design (231 x 199 x 97 mm) ensures silent and reliable operation of the system.

Backplane Systems Technology Pty Ltd Contact info and more items like this at wf.net.au/V358

PROCESS WORKFLOW SOFTWARE Proficy Workflow Version 2.1 software digitises and streamlines production, with one tool, and is designed to integrate business and production processes across systems and departments for reliable, repeatable process execution. It makes it possible to integrate existing automation and control systems, speeding response to out-of-spec HMI/SCADA conditions with appropriate action.

It can assist in real-time asset management, bridging operations and maintenance, and linking SCADA and CMMS, improving uptime. Its task management capabilities allow users to capture the best practices of experienced operators and guide all workers with step-by-step instructions.

The latest version provides improved performance and scalability for large system deployments, allowing companies to replicate production processes across their organisation for increased consistency, quality and efficiency.

It offers improved capabilities for enforcing and tracking operator compliance, particularly important in highly regulated industries. Companies can verify documents and actions through enhanced electronic signatures, allowing them to move faster from critical issue detection to resolution thereby potentially decreasing the size of a recall or even preventing one.

Proficy Workflow is also said to provide significantly greater ease of use for defining and managing tasks, allowing companies to digitise operational processes faster and without IT resources. Production experts can more easily document processes, leveraging a simple graphical environment and re-usable templates.

GE Intelligent Platforms Asia Pacific Pte Ltd Contact info and more items like this at wf.net.au/V372

20 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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NEW PRODUCTS

SAFETY ISOLATORS Moore Industries’ SSX and SST safety isolators and splitters provide reliable isolation and signal conversion for HART data in functionally safe process control settings. The 2-wire (loop-powered) SSX and 4-wire (line/mains-powered) SST have been certified by exida for single use in safety instrumented systems up to SIL 2. Comprehensive FMEDA-certified safety data is available on request.

The SSX and SST family protects safety systems by isolating an SIS from basic process control or monitoring systems so that disconnections or other failures don’t impact the safety system. It also has 1500 VRMS of isolating capability to protect safety I/O cards and systems from surges, spikes and transients in the field. Standard 20 V/m RFI and EMI protection stops damages caused by radio frequencies and electromagnetic interference.

Sending HART data is critical for diagnostic and preventative maintenance. While most isolators ‘strip off’ HART data, the SSX and SST pass along HART data to asset management systems, programming devices or host systems.

In addition, the SSX stops ground loop noise and solves bucking power supply problems caused when two devices try to source power to the same loop.

The 4-wire SST splitter takes the input from one process signal and creates two identical, isolated outputs that can go to two different monitoring or control devices. It can also serve as a HART splitter to pass HART data to one or both independent outputs.

Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/U798

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NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

PERSONAL GAS DETECTORS

WHY TWO SENSORS ARE SAFER THAN ONE Raghu Arunachalam, PhD, Global Director of Multi-Gas Solutions, Industrial Scientific Corporation

Manufacturers of personal gas monitors typically recommend that gas monitors be bump tested prior to each day’s use and calibrated at least monthly.

But how necessary is daily testing and how does it affect safety?

I

n environments where there is a risk of harmful gas exposure, it is essential to use personal gas monitors to keep people safe, and so the regular maintenance of gas monitors is necessary if they are to perform their lifesaving function.

The industry standard practice for maintaining gas monitors is to perform periodic calibration and to perform regular functional tests (otherwise known as ‘bump’ tests). The role of calibration is to ensure the continual accuracy of the gas monitor, but a bump test verifies that the monitor is in fact working properly by checking that the sensors are responding to gas and the monitor is alarming appropriately.

In practice, most use cases of gas monitors are more concerned with detection and alarming as opposed to reading the exact concentration of gas, since the primary purpose of many gas monitors is as personal protection equipment (PPE). Calibration and bump tests are both performed by exposing the monitor to a measured concentration of gas and verifying the response, and may be done manually or through automated test equipment such as docking stations. Manufacturers typically recommend that gas monitors be bump tested prior to each day’s use and calibrated at least monthly.

But how realistic are the manufacturers’ recommendations? And

22 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

do the users of the gas monitors actually comply with these recommendations? After all, if users don’t comply then the recommendations only serve in covering the manufacturer from potential liability.

It does nothing to keep the end user of the gas monitor any safer.

So the question then becomes whether the testing interval impacts safety in a real way.

Real bump test practices To find out how gas monitors are being tested, Industrial Scientific Corporation studied more than 25,000 gas monitors used in the field over a period of two years. It found that about 20% of users bump tested their monitors prior to each day’s use, while 15% never bump tested. The rest of the users’ practices fell somewhere in between, with the average user bump testing once a month (see Figure 1).

This raises the question: why is the level of compliance with manufacturers’ bump test recommendations so low? There are a number of contributing factors: 1. Education/training.

2. Practicality of performing a bump test before each day’s use.

3. Costs in time and money.

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© iStockphoto.com/ANDRS EDUARD

Gas detection

As is the case with most safety practices, education and training is essential and must be ongoing. Nevertheless, it was found that despite education and training, the practicality and cost of bump testing were even more significant barriers to complying with a manufacturer’s bump test recommendations.

In many applications, users work remotely in environments that prevent them from being able to bump test their instruments and make it difficult for their supervisors to monitor that these tests are in fact being performed as prescribed. In other applications, particularly where large gas monitor fleets are involved, it is a logistical challenge to ensure that all monitors are bump tested at the start of each day. While calibration docking stations have helped to automate and simplify this process, it comes at a cost. This is particularly true in the case of single gas monitors where fleets are large and docking stations add significantly to the cost of ownership.

What are the risks of not bump testing?

It seems to make sense that more regular bump testing would be safer because there is higher likelihood of discovering faulty de-

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tectors. But is there a big difference between bump testing every day versus every week? What about every month?

The results of more than 2 million bump tests conducted in the field were studied. This study involved sensors manufactured by a number of manufacturers and focused on widely used electrochemical and catalytic sensors. The risk was measured by determining the average instrument use days before a failure for a given bump test schedule (see Figure 2).

It was found that users that bump test their instruments every day experience an average of one failure per 1253 instrument use days (about 3.5 years). Users that bump test once a month experience on an average of one failure per 286 instrument use days. This means that a vast number of users today are over four times less safe than they can be if they bump tested prior to each day’s use.

It is important to point out that bump testing every month will not necessarily result in an injury or fatality every 286 days - the user would need to be exposed to harmful levels of gas, as well.

Nevertheless, it is apparent that the monthly bump test schedule adds to the risk factor.

So frequent bump tests are important, but only about 20% of users (at best) bump test prior to each day’s use. Further, a vast majority of these users are aware that they should be bump testing every day but they simply cannot due to operational and cost challenges.

Dual sensor technology Sensor failures are by far the greatest cause of gas detector failures. All major manufacturers of gas monitor sensors use similar technologies - the vast majority of these being electrochemical sensors (used to detect H2S, CO, O2, etc) or catalytic bead sensors for explosive gas detection. These sensors have been around for a number of years and, as such, are well understood. Their primary appeal is that they are simple, cheap and reasonably reliable as long as regular bump tests are performed. While newer sensors with cutting-edge technology seem perpetually on the horizon promising significant benefits, the ready availability and cost-effectiveness of traditional electrochemical and catalytic sensors make them the mainstay of the industry.

By adding sensor redundancy, the safety and maintenance challenges of current gas monitors can be overcome. The two different sensors sense the same gas and provide simultaneous readings to the monitor electronics that applies a proprietary algorithm to calculate and display a single reading. The dual sensor technology, in conjunction with a daily self-check that verifies proper operation of the monitor electronics and alarms, makes for a vastly safer and more cost-effective monitor.

How much safer is a user of a single gas monitor with dual sense technology than a user of a traditional single gas monitor with a single sensor? Let us take the case of a traditional single gas monitor and compare it to an instrument with ISC’s DualSense Technology. Using the data presented in the previous section on

NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

Gas detection

Figure 1: Percentage of gas detectors bump tested before use.

Figure 2: Average number of instrument use days before failure versus bump test frequency.

BY ADDING SENSOR REDUNDANCY, THE SAFETY AND MAINTENANCE CHALLENGES OF CURRENT GAS MONITORS CAN BE OVERCOME.

Figure 3: Failure rate comparison – monitor with DualSense technology versus traditional monitor.

failure rates, the failure rate for DualSense-based monitors can be calculated. Figure 3 compares the safety of the two types of monitors in terms of average instrument use days before failure.

In the case of both monitors - those with DualSense Technology and those with a single sensor - in which they are bump tested before each day’s use, we can expect one failure in over 300 years for the instrument with DualSense Technology as opposed to one failure in 3.5 years with the traditional instrument. If the aforementioned monitors were bump tested every month then, on an average, the failure rate of the instrument with DualSense Technology is one failure in just under six years compared to one failure in 286 days for traditional gas monitors.

It is apparent from Figure 3 that the monitor with dual sensors is much safer than a traditional single gas monitor irrespective of bump test schedule. On average, the instrument with DualSense Technology is 85 times safer. Even in the extreme comparison of a traditional monitor that is bump tested every day versus a dual sensor monitor that is bump tested every month, the latter is 17 times safer than a traditional monitor. It is clear then that incorporating dual sensor technology is a cost-effective means to significantly improve safety of a gas monitor in real-world conditions - conditions where it might or might not be possible to perform a bump test before each day’s use.

24 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

The ready availability of working gas monitors is a critical part of keeping production lines and drilling rigs, for example, working.

Without working monitors, productivity might go down, costs might increase with the need for back-up instruments within the fleet or, at worst, a user goes into the field to do work with no instrument at all. A redundant sensor provides a short-term solution when one sensor fails for people to still be able to go out and do their jobs, though overall safety must be maintained by performing more frequent bump tests. This is analogous to a spare tyre in a car. It is a valuable back-up and means the car is available to drive though it must be driven with some constraints - driven at a slower speed and for a short distance.

Summary It is clear that bump tests are critical in establishing that instrument sensors react appropriately to gas and that the instrument alarms before it is relied on to keep its bearer safe; but at best, about 20% of users of gas monitors perform bump tests prior to each day’s use. About 15% (probably more) never perform a bump test at all.

Users who bump test every day can expect, on average, one failure per instrument every 3.5 years, but given the low frequency of bump tests performed in the field, the reality is that a number of gas monitor users are putting their lives at risk every day.

Irrespective of bump test frequency, an instrument with dual sensors is safer than a traditional monitor (85 times safer on average).

Industrial Scientific Corporation Contact info and more items like this at wf.net.au/V417

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NEW PRODUCTS

AUTOMATION PC B&R has developed a new genre of industrial PC without cooling fans, ribbon connectors, mechanical HDDs and even the Windows operating system where possible.

The APC910 also has features such as scope for a built-in UPS and the ability to place multiple displays up to 100 m away.

Entry-level models feature the economical Celeron CPU, which is sufficient for common applications like SCADA. Models with the Core i-series CPU additionally give the unit the capacity for demanding real-time applications such as motion, robotics and vision systems.

B&R Runtime technology is claimed to merge the best attributes of PLC with an automation PC, but without PLC constraints. As a fully fledged PLC operating system that runs without Windows, this PC-based controller is free of the typical PLC and Windows limitations.

With the APC910 it is possible to run a PLC and SCADA on the same PC. Hypervisor technology enables B&R Runtime to co-exist cooperatively with other operating systems on a single PC unit, offering significant project savings.

Daanet Pty Ltd Contact info and more items like this at wf.net.au/V408

MACHINE CONTROL SOFTWARE The latest version of Allen-Bradley IntelliCenter software integrates added features - IntelliCenter Integration Assistant and IntelliCenter Energy - designed to accelerate the configuration time and enhance end users’ data-driven energy decisions.

With IntelliCenter Integration Assistant, users can seamlessly integrate their IntelliCenter motor control centres (MCCs) into their Rockwell Software RSLogix 5000 programming software. This feature reduces programming time by automatically adding the Allen-Bradley Centerline MCC devices to the RSLogix 5000 I/O tree. In addition, Integration Assistant also takes advantage of existing integration features to automatically create controller tags and IP address configuration in RSLogix 5000 software, reducing errors and the time it takes to configure the intelligent devices.

IntelliCenter Energy offers a preconfigured set-up of FactoryTalk EnergyMetrix software for intelligent motor control devices in the MCC, including variable speed drives, overload relays and SMCs. In addition, users can view energy consumption at the device level directly from IntelliCenter software. With IntelliCenter Energy, it becomes easier to monitor and manage energy usage in the industrial facility for cost savings and allows for easy integration of IntelliCenter MCCs into plantwide energy-management systems. IntelliCenter Energy gives users the information necessary to make fact-based decisions to help them optimise energy usage, improve equipment performance and even predict equipment failure.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/V297

PHOTOELECTRIC SENSORS Banner Engineering S18-2 series compact photoelectric sensors are self-contained, DC-operated sensors that provide an economical sensing solution for cost-sensitive and high-volume installations. Built with advanced ASIC technology, the diffuse mode sensors are resistant to fluorescent light and offer a high level of crosstalk avoidance.

The sensors feature a powerful and bright, visible red emitter beam that reaches up to 25 m, which allows for easy alignment and set-up. For ease of use, the sensors also offer a highly visible output, and dual-function power and stability indicators. The indicators are comprised of one green and two yellow LED lights. Solid green indicates power is applied and the sensor is ready, while green flashing specifies a marginal sensing signal. The two bright yellow LEDs, visible from both sides of the sensor, indicate the output is conducting.

Featuring a rugged ABS plastic housing, the sensors are well sealed against water ingress. A wide operating temperature range of -40 to +70°C ensures optimal performance for diverse applications. For increased flexibility, diffuse models provide a robust 250° sensitivity potentiometer.

Micromax Pty Ltd Contact info and more items like this at wf.net.au/V291

26 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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Served up on a plate

AirLINE Quick: High quality, cost effective, fast delivery Meet AirLINE Quick. AirLINE Quick has internalised all pneumatic air channels, and integrated primary and secondary components to deliver one single complete pneumatic (or electro-pneumatic) valve bank on a stainless steel adapter plate. Unlimited modularity in valves, functions, feedbacks, I/O, and accessories, is offered, with local assembly from Bürkert’s ISO 9001 Sydney Systemhaus. The stainless steel plate mounts directly into a cabinet, effectively minimising labour for cost effectiveness and fast delivery.

Same day turn-around (on lower-quantity orders) is common.

Last year Bürkert shipped around 600 panels, and this year with AirLINE Quick it could easily be thousands. Call us, and get your valve banks served up on a plate, or mounted in a cabinet, ready to go.

Ideal for end-users, OEMs, and switchboard consultants. Designed for arduous environments, for physical and chemical resistance.

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

We make ideas flow

CASE STUDY

Novel ethernet-based motion control architecture improves plastic bag machine

Modern plastic bag-making machines often have two servomotor based axes - web feed and cut/seal - plus a mechanically linked third axis for ‘picking off’ the finished bags. UK machine builders Hartech Engineering and GPL Machinery have cooperated in a joint development of a machine that also implements servo control on this third axis to provide programmable ‘electronic cam’ control of pick-off action.

Allowing users to finely adjust pick-off, the machine can avoid the sealing problems that commonly arise as machines are set up to handle different types of blown or cast film materials, thus minimising scrap and downtime.

The machine (known as BBM1100) is built on the mechanical framework of a common bag-making machine from Woodbank (which ceased production around a decade ago). There are many of these old machines in the UK, which GPL and Hartech have been servicing and refurbishing for more than a decade. During this time, the two companies have developed numerous add-ons and upgrades based on ABB motion control technology, including replacement servomotor axes and a new user interface. Based on ABB’s Ethernet Powerlink compatible motion control range, the new machine features an all-servomotor architecture and a user interface developed from the operator’s point of view.

The re-engineered all-servo machine not only offers inherently finer control over manufacturing - and as a result quality and productivity - than previous machines, it is also price-competitive, costing up to 30% less than a brand new machine.

The machine’s three axes are powered by drives from ABB’s 3-phase MotiFlex family, linked to the company’s BSM brushless servomotors. Control is provided by the ABB NextMove e100 machine controller with a touch-screen colour operator panel.

The Ethernet Powerlink interfaces of ABB’s drives and machine controller provide one major benefit. Through their single network cable interface they substantially reduce cabling to speed system building and lower hardware costs, and simplify subsequent machine commissioning as well.

The ABB NextMove controller also includes enough onboard digital and analog I/O to satisfy the bag-making machine’s I/O requirements. In addition, a high-speed digital input on the drives provides a direct interrupt that captures positions to within a microsecond resolution. This feature is used to support high-speed print registration on the BBM1100 - which will operate right up the machine’s fastest production rate.

The developers also greatly value ABB’s MINT programming language, which provided the machine with high-level keywords for many of the motion control operations employed during the bag-making cycle. For instance, one of the keywords used in the control software for this new machine architecture is SENTINEL, which allows events to be triggered under software control. In this case, SENTINEL synchronises the pick-off axis to a virtual line shaft acting as a ‘master clock’ for the machine cycle. This allows users to program the profile of the electronic cam with high resolution and precision, rather than being limited by a fixed-profile mechanical cam. It ensures that the machine can be configured to operate in the optimal way for the exact type, grade and thickness of plastic material being processed.

“ABB provides us with motion components offering genuine real-time performance, plus support for the complete motion control

28 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

package - all from a single point,” says GPL Machinery’s Graham Levine. “It’s helped us to bring our new machine to market both efficiently and rapidly.”

In addition to implementing core performance features in the new machine, the design team has emphasised usability and reliability throughout the design. For example, the user interface has been developed from the point of view of the operator. The machine can be set up for a new batch with just a few touches on the control menus. Operators can also change action on the fly, to adjust the print registration for instance, or the dwell time of the cut and seal bar. Users also have access to deeper configuration possibilities via a password-protected screen. This can be used for purposes such as changing the action of the pick-off belts - the grip speed, acceleration and deceleration profile, for example. Such settings can be saved and renamed so that operators are able to load a proven bag-making setting for any particular job or material within seconds.

A number of hardware features also endow the new machine with high reliability. Bag-making machines have an inherent stop/start movement and there is always a degree of vibration. So, the machine builders avoided some of the more modern but more fragile feedback technologies and instead chose to use resolver feedback to measure rotational position.

The re-engineered BBM1100 machine is a first step for GPL Machinery and Hartech Engineering. The two companies already have plans for an all-new own-brand machine, which will feature a mechanical chassis of their own design and a number of new advanced features for this segment of the packaging marketplace.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/V311

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NEW PRODUCTS

COMBINED LIGHTNING AND SURGE ARRESTER The DEHNvenCI combined lightning current and surge arrester with integrated backup fuse combines maximum system protection and compact dimensions in a single device.

The DEHNvenCI is a combined lightning current and surge arrester with a discharge capacity up to 25 kA (10/350 Âľs) and combines system protection and compact dimensions in a single device. Each arrester including integrated backup fuse only takes up two standard DIN modules.

The need to select and install arrester backup fuses is eliminated, ensuring short connecting cable lengths as required in AS/NZS 3000 and IEC 60364-5-53. DEHNvenCI is an efficient combined lightning current and surge arrester that is easy to install.

Energy coordinated with downstream terminal equipment is guaranteed using the DEHNvenCI with distances ≤5 m between the primary protection and the terminal device. The ability to carry lightning impulse currents without destruction and simultaneously reduce the energy to an acceptable level for terminal equipment ensures the availability of installation in case of a direct lightning strike.

The patented RADAX Flow technology ensures 50 Hz follow current limitation and extinction and thus high system availability, even in the case of short-circuit currents as high as 50 kARMS. The operating status indicator on DEHNvenCI provides information about the integrity of the arrester even if no operating current is present.

Apart from the standard visual indication with green and red indicator flags, the arrester features a potential free remote signalling contact.

DEHN + SOHNE GmbH + Co KG Contact info and more items like this at wf.net.au/V059

Sensor Monitoring Services

Industrial Control ZigSense cloud controller is an

Energy Metering

Refrigeration

Tank & Silo Level

HVAC Cold Storage Building Automation Water Metering

out-of -the-box solution ready to operate independently or as an interface station between remote ZigSense wireless sensors and ZigCloud online monitoring services sites.

Users gain access to live or historic data generated by the monitored process.

ZigCloud enables the user to define online: Alarms, Reports, Graphs and Charts. Users receive alert messages and reports via email, SMS or voice.

Interface to other devices is Modbus ready.

Gas Monitoring Pollution Horticulture Aquaculture

ZigSense and ZigCloud are business units of Conlab Pty Ltd 13/1020 Doncaster Road, Doncaster East, Victoria 3109 Australia Ph: +61 3 9842 7711 Fax: +61 3 9842 7511 www.zigsense.com.au Email: info@zigsense.com.au

30 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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NEW

REMOTE TERMINAL UNIT

PRODUCTS

The Simatic CP 1243-1 DNP3 from the Siemens TeleControl Professional product range connects the controller to a control centre, such as a process control system, via DNP3 (Distributed Network Protocol). A typical use case for this is the transfer of measured values in widely spread outdoor areas to a central station, for example in sewage and water treatment plants, district heating networks and pump stations, as well as in oil and gas supply, energy distribution and transportation systems.

Simatic CP 1243-1 DNP3 transfers measured values, setpoint values and alarms to the control station cyclically or event-based. In the STEP 7 engineering tool, the user selects the data to be transferred from the Simatic S7-1200 CPU and specifies the required communication parameters.

Communication with the control centre is based on DNP3 specification 2 (2007/2009). The communication processor also has an email function, for example, to inform maintenance staff automatically about previously defined events, such as threshold values being exceeded.

Simatic CP 1243-1 DNP3 can buffer up to 64,000 values with time stamp in order to prevent data loss when a connection fails. When the connection is re-established, the buffered values are automatically transferred to the control centre in the right chronological order. Comprehensive diagnostic options, locally via LEDs or in the STEP 7 engineering tool, offer the user fast and clear analysis of the station status.

The communication processor is connected to the local communication network in the outdoor area via an ethernet interface.

Siemens Ltd Contact info and more items like this at wf.net.au/V186

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NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

NEW PRODUCTS

ROTARY FEEDERS The Aero-Flow Series of rotary feeders is designed specifically for pneumatic conveying of dense materials such as fine powders used in chemical and pharmaceutical processing, food and bakery processing, plastics, and milling. It provides highly efficient, airassisted, material introduction to pneumatic conveying systems.

The ACS Aero-Flow Series of rotary feeders uses a proprietary, dual-induction endplate design to introduce pressurised air from both endplates into the rotor pockets carrying process material. The high bulk density material, when mixed with air, is more effectively released from the rotor pockets and is more efficiently introduced to the pneumatically conveyed material flow. The Aero-Flow Series dual-induction design speeds the material fluidisation process, improves material consistency and optimises feeder energy consumption when compared to conventional, single-induction feeder designs.

Further energy efficiency is provided by an available ACS variable frequency drive to modulate the feeder drive speed and reduce power requirements based on the fluctuating performance needs of the system.

ACS Aero-Flow feeder housings are available in cast iron and 304 or 316 stainless steel; in either 44 or 54 cm heights. They provide optimal service in applications with pressure differentials up to 15 psig and elevated temperatures to 260째C. The Aero-Flow Series 10-vane rotor is precision machined with bevelled vane tips and sides. Other rotor configurations include Tefloncoated and adjustable tips. Adjustable rotor tips are available in hardened steel or stainless steel. Rotor housing interior surface coating options include hard chrome, tungsten and Teflon.

ACS Valves http://www.acsvalves.com/

DISTRIBUTED I/O The Simatic ET 200SP distributed I/O system has been expanded with additional communication modules for the AS-Interface and IO-Link, as well as a version for extreme conditions.

The CM AS-i Master communication module is used for connecting actuators and sensors compliant with the AS-Interface profile to Simatic ET 200SP. For safety-oriented applications, the F-CM AS-i Safety version can be used.

The IO-Link master module enables actuators and sensors compliant with the current IO-Link specification V1.1 to be connected to Simatic ET 200SP. One feature of the ET 200SP is that the master parameters are automatically backed up.

This means that a module can be swapped from the master or devices without the need for a programming device or having to restore the data in the user program. The IO-Link master module continues to support IO-Link devices according to specification V1.0.

For use in hostile industrial conditions, such as high temperatures, high humidity or corrosive gas atmospheres, the Simatic ET 200SP distributed IO system has now been expanded to include Siplus ET 200SP. This version avoids derating, for example, at extreme temperatures.

Siemens Ltd Contact info and more items like this at wf.net.au/V117

32 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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NEW PRODUCTS

MODULAR MODBUS I/O SYSTEM PROBUS from Procon Electronics is a modular Modbus I/O system that provides a simple low-cost solution for distributed I/O requirements.

Manufactured in Australia, the PROBUS system consists of standalone digital and analog input and output modules which are connected together on an RS485 two-wire, multi-drop network.

The modules plug into a special bus connector which fits inside the DIN rail.

The modules communicate using the Modbus RTU protocol. A 32 bit ARM CPU is used in the modules to provide high-speed data processing and fast communications turnaround times. Multiple baud rates are selectable from 2400 to 115,200 baud.

All PROBUS modules plug directly onto an industry-standard DIN rail. All modules have a minimum isolation of 1500 VAC between the field and logic and all RS485 circuits are isolated. The modules have been equipped with status LEDs which are used to indicate the status of the inputs or outputs.

The I/O capabilities of a PLC can be expanded where the PLC has a Modbus communications facility available. When configured as a Modbus Master, and attached to the RS485 network, the PLC can use the PROBUS modules as remote I/O, reducing cabling costs and increasing the I/O capability of the PLC. The PROBUS modules can also be used for distributed data acquisition by connecting a PC to the network through an RS232/RS485 converter. Procon also offers an ethernet converter to allow the PROBUS modules to communicate over a 10/100baseT network.

Procon Electronics Pty Ltd Contact info and more items like this at wf.net.au/V119

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NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

NUMERICAL SIMULATION

ENABLING CONTINUOUS MANUFACTURING IN THE PHARMACEUTICAL INDUSTRY Sabine Goodwin and Dr Kristian Debus*

In the pharmaceutical industry, traditional batch manufacturing processes are proving to be too inefficient for today’s world of economic pressures and increased global competition. There is no question that continuous manufacturing is the path forward towards leaner processes.

T

he batch-based systems currently in place in the pharmaceutical industry are inefficient due to segmented steps involving multiple facilities and requiring start and stop of the batch, site-to-site transfer and warehouse storage. Product quality assessment is also cumbersome, because it is performed through sampling and in post-production, causing long lead times and waste.

Moving away from batch processing to a continuous, non-stop, end-to-end manufacturing process, however, could modernise the industry and solve its crisis of productivity. Josef Jimenez, CEO of Novartis, recently stated that changing production from batch to continuous will transform the way medicines are made around the world. He said it could cut the time from development to market-entry in half.1 Implementation of these processes will result in smaller production plants, lower inventory costs, reduction in carbon footprint and higher quality products. 2 New moves by regulatory agencies are encouraging the development of new manufacturing technologies by building quality into the process and using a science-based quantified risk approach, by starting to lay the groundwork for continuous manufacturing with several initiatives, 3,4 and with regulatory

34 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

frameworks such as process analytical technology (PAT) and quality by design (QbD).

Both the chemical and food processing industries have been improving their productivity by successfully integrating continuous manufacturing into their plants. It is clear that regulatory hurdles and conservative thinking by the pharmaceutical industry can no longer be used as an excuse to avoid taking pharmaceutical manufacturing into the 21st century.

Predicting process behaviour through numerical simulation For continuous processing to become possible, potentially suitable processes must be identified and designed, and the associated risks need to be analysed and mitigated, in order to make a business case for implementation, and to manage regulatory compliance. Multiphysics computational fluid dynamics (CFD), a numerical method for predicting the coupled behaviour of fluid, gas and particulate flows including heat and mass transport, offers a solution for the enhanced understanding and design of these processes. It is emerging as game-changing technology to help continuous manufacturing for active pharmaceutical

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Pharmaceuticals

© iStockphoto.com/Factoria Singular

Design exploration and optimisation

ingredients (APIs) become a reality through virtual prototyping, optimisation and modelling of the complete system.

Virtual prototyping Numerical simulations enable the engineer to build a virtual laboratory, providing insight into the performance of a product before tests are carried out. This means that the uncertainty resulting from major process and equipment changes can be evaluated up front, leading to a significant risk reduction and cost savings. Contrast this with traditional manufacturing processes that are based on the ‘design-build-test’ principle - in which the effects of design changes are quantified by experimental tests on physical prototypes. Physical prototyping in the pharmaceutical manufacturing context is anticipated to be very costly.

Multiphysics CFD and state-of-the-art visualisation tools also offer a wealth of detailed information, not always readily available from laboratory or experimental tests. This not only results in an increased level of insight into the details of what is going on inside processes, it also enables innovation. For example, multiphysics CFD can help explore new reactions and molecules for drugs manufactured with a continuous process.

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The maturing of robust simulation tools and the increase in computing power over the years have made it possible to use numerical design optimisation in production environments.

Parameter studies and optimisation will be vitally important for designing and tuning of the new (often smaller) equipment required for continuous manufacturing while ensuring that the operation can efficiently handle fast reactions and remains flexible. In addition, the CFD-generated responses - obtained through design of experiments over a range of operating conditions and equipment design parameters - can be combined with statistical models to identify risk and implement robust real-time process control. This will ultimately result in reduced variability and consistent, repeatable processes.

There are now tools that enable intelligent design exploration and to easily consider ‘what if’ scenarios so as to identify the critical manufacturing points that define quality. For example, feeding devices for continuous manufacturing influence all downstream operations, and design exploration of parameters such as feed rate will help identify their impact on final blend uniformity.

Simulating systems Solving complex real-world problems demands an accurate, easy-to-use, multidisciplinary approach to simulating complete systems. CFD-focused multiphysics engineering simulation tools such as STAR-CCM+ can accurately deliver full spectrum engineering results and the pharmaceutical industry should fully leverage these tools in support of the development of continuous manufacturing processes.

Up until now, integration of numerical simulations in a production environment has required a great deal of specialised knowledge, but this is no longer a showstopper. Automation and ease of use are enabling the deployment of CFD for complex multiphysics applications. For example, STAR-CCM+ offers stateof-the-art meshing, seamless integration with CAD and easy modelling of complex moving parts, all in a single integrated environment. The net result is more time for an engineer to analyse data instead of preparing and setting up the simulations, resulting in engineering success.

Seeing the ‘big picture’ for continuous manufacturing will require a multiphysics approach to solving problems. Be it mixing, coating or drying, multiphase flows lie at the core of the pharmaceutical processing industry. Capabilities such as discrete element modelling (DEM), a numerical method for computing the interaction of a large number of small particles, and Eulerian multiphase modelling (EMP), a numerical method for simulating several phases in a system, will be invaluable for implementing continuous manufacturing of APIs. Two case studies are presented next to demonstrate these capabilities.

NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

Pharmaceuticals

Figure 1: Simulation showing tablet velocity as they tumble in a coating pan.

Figure 2: DEM simulation showing pill coating thickness in a fluidised bed.

Case study 1: Direct element modelling (DEM) for pill coating DEM simulates the motion of a large number of interacting particles and tracks them in a numerically efficient manner, modelling contact forces and energy transfer due to collision and heat transfer between particles. DEM will be particularly important in the design and optimisation of continuous coating processes to help identify the important factors for equipment design (such as the number of spray guns) and to determine optimal equipment operation conditions (such as inlet temperature).

Figures 1 and 2 show STAR-CCM+ generated solutions for two types of equipment currently used for real-world tablet coating: coating pan (rotating drum) and fluidised bed. In these simulations, DEM is used to analyse the random movement of the particles as layers of coating are applied. Parameters such as particle velocities, residence time and coating thickness are tracked to assess and improve tablet coating uniformity. In addition to tablet coating, DEM can also be used to simulate other steps in manufacturing such as filling, filtering and conveyor processes.

Case study 2: Eulerian multiphase (EMP) modelling for mixing EMP modelling provides an effective means for studying the interacting streams and randomly dispersed phases in multiphase flows. The EMP model in STAR-CCM+ includes an extensive range of submodels including break-up and coalescence models for bubbles and droplets and a granular flow model for particles. Figure 3 demonstrates an EMP simulation of a gas-liquid mixer with three rotating impellers.

Shown are the effects of increasing gas injection rates on gas. The ability to predict gas hold-up, a parameter that governs mass transfer across the phases and consequently rates of reaction, is a key enabler in the design of such reactors. This approach adds valuable scientific insight into the decision-making criteria to develop practical solutions for mixing and other processes in continuous manufacturing.

Conclusion In today’s competitive climate, manufacturing must become leaner with a focus on building quality into the process. Continuous manufacturing for the pharmaceutical industry will change the way drugs are made and multiphysics CFD simulations offer a cost-effective

36 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

Figure 3 : Mixer model showing the effects of increasing gas injection rate. way to perform rapid prototyping for design of new equipment and processes. In particular, design optimisation tools and powerful multiphase models such as DEM and EMP will play an important role, and the pharmaceutical industry should fully leverage these state-ofthe-art technologies for the design and implementation of continuous manufacturing processes.

References 1. Jimenez, J 2012, ‘A Defining Moment : The Future of Manufacturing in the US’, conference presentation, The Future of Manufacturing in the US, MIT, 8-9 May. 2. Plumb, K 2005, ‘Continuous Processing in the Pharmaceutical Industry : Changing the Mindset’, Chemical Engineering Research and Design, vol 83, pp 730-738.

3. Woodcock, J & Woosley, R 2008, ‘The FDA Critical Path Initiative and its Influence on New Drug Development’, Annual Review of Medicine, vol 59, pp 1-12.

4. US Food and Drug Administration, Pharmaceutical cGMPS for the 21st century: A Risk Based Approach, <http://www.fda.gov/drugs/ developmentapprovalprocess/manufacturing/questionsandanswersoncurrentgoodmanufacturingpracticescgmpfordrugs/ucm137175.htm>. *Sabine Goodwin is a Senior Engineer, Technical Marketing, and Dr Kristian Debus is Director, Life Sciences, at CD-adapco.

CD-adapco Australia Contact info and more items like this at wf.net.au/V333

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NEW

PANEL PC

PRODUCTS

The Aplex APC-3565 rugged industrial panel computer is housed in a fan-cooled steel case that provides IP65 front panel protection. It is supplied with an internal 15″ XVGA 1024x768 resolution LCD. An optional resistive touch screen is also available making it suitable for operator panel and HMI control applications.

The APC-3565 features a built-in energy efficient Intel dual core Atom D2550 1.8 Ghz processor with 2 GB of DDR3 memory. An internal 2.5″ hard-drive bay and an external CompactFlash slot are provided for system and data storage. Rear I/O connections include four COM ports, four USB 2.0 ports, two Gigabit Ethernet ports, a VGA port and PS/2 mouse and keyboard ports. Two PCI slots are provided allowing add-in cards to be installed. The panel

ENCODER

computer operates from an 11-32 VDC power source.

The Hengstler RF53 Motor Feedback Encoder is an incremental encoder

The panel computer can operate in temperatures ranging

designed to provide reliable feedback of the motor’s position to its control

from -20 to 60°C when using an industrial SSD for stor-

system. High motor speeds are easily handled with an output of up to

age. An optional 6 cm cooling fan can also be installed

10,000 ppr and a maximum speed capability of 12,000 rpm.

if required.

With an IP54 housing diameter of only 53 mm, the stainless steel and

Flexible mounting options allow the APC-3565 to be

aluminium encoder provides a lightweight (200 g) solution for applications

panel or rack mounted while VESA 75x75 rear mounting

subject to temperatures of up to 120°C and vibrations of 25 m/s 2. The

holes allowing the panel PC to be securely arm mounted.

encoder is easy to install via its rear spring tether and it couples to the

The panel computer is compatible with Windows operating systems allowing it to support a wide range of off-the-self

load with a centre bolt shaft.

The encoder supports both AC-synchronous and BLDC motors, and

and custom-developed industrial applications.

utilises both commutation and incremental methods of encoding.

Interworld Electronics and Computer Industries

Automated Control Pty Ltd

Contact info and more items like this at wf.net.au/V196

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NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

CASE STUDY

Steel furnace upgrade benefits from easier wiring

The steel plants of Saarstahl at Völklingen, Burbach and Neunkirchen have been producing steel products in the Saarland region of Germany since the late 19th century and specialise in the production of wire rod, steel bars and semi-finished products of various grades. Saarstahl is considered one of the most important manufacturers of long steel products in the world. The product range also includes open die forgings. These products are important preliminary products for the automotive industry and its suppliers, the construction industry, power industry engineering, the a e ro s p a c e i n d u s t r y , g e n e ra l mechanical engineering and other steel-using industries.

Industrial service provider s c h ü t z e n g i n e e r i n g P LT w a s engaged in a modernisation project at the Saarstahl Burbach plant and was looking for a suitable connectivity solution for signal distribution. In the end the PRV PUSH IN marshalling terminal blocks from Weidmül ler were selected.

T h e 92 M W w a l k i n g - b e a m furnace in Saarstahl’s Burbach plant places very high demands on the process control system with its 14 control zones. Saarstahl contracted schütz engineering to modernise the Contronic 3 measurement and control system made by Hartmann and Braun in 1996. The industrial service provider was able offer Saarstahl a complete package, using its experts for furnace systems, that was tailored to the customer’s requirements. For the area of marshalling, the maintainers had a clear wish: the use of terminal blocks.

“During maintenance and servicing, terminals are simply easier to operate,” stated Peter Altmeyer, leader of EM maintenance and power supply at Saarstahl. “So that we could wire both securely and quickly, we wanted a connection solution with screwless direct insertion technology. The PRV marshalling terminal block from Weidmüller which schütz engineering presented to us met these requirements exactly. It impressed us, not just with its push-in connection method, but also with its compact design. Its shape means that it is ideally suited for installation into the existing space in our electrical cabinets.

There was even enough space for spare inputs, so that any future expansions can be directly incorporated into the system.”

To avoid downtime, the conversion of the measurement and control system was to take place during the summer holidays,

38 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

when there was a 14-day shutdown of the walking-beam oven.

The PRV terminals also had benefits when it came to the tight time period for conversion, signal testing, recommissioning and control circuit optimisation.

“The existing wiring to the electrical cabinets had to be reinstalled one for one. Instead of the standard web-like colour variants, Weidmüller delivered us terminals with striped colour markings. As the existing connection elements were also constructed with a white-red striped colour scheme, the rewiring could be carried out quickly and without complications. The rewirers were almost able to work without a circuit diagram,” recalled Franzjosef Haas from schütz engineering about the seamless project flow. “We connected 5600 terminal points in 32 hours from the start of disassembly to the beginning of signal testing.”

For running operations, the PRV terminals offer an operating and maintenance friendly solution.

Thanks to the high connection density, there was always a danger in the TERMI-POINT versions used previously that a short circuit could be caused during maintenance work in a running plant. This was because the terminals in the measurement system circuits were constructed in such a way that these short circuits could lead to false measurements and even shutdowns for plant components; this could lead to major damage in the worst cases.

The PRV PUSH IN marshalling terminal blocks, on the other hand, prevent wiring errors successfully and do not need special tools for the re-wiring. The previously prepared conductors are simply inserted into the terminal points and a vibrationproof and gas-tight connection is made. A normal screwdriver can be used to release the connections.

“The colour coding of the connections was tailor made to meet our requirements. This and the simple operation of the connection technology in the PRV system made a major contribution to us being able to meet the 14-day deadline for the customer without any problems,” Haas went on. “The additional improvement in plant security meant that we were able to offer our customers a solution which was suitable all round.”

Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/V348

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NEW PRODUCTS

ROBOT HMIS WITH SMARTPHONE SIMPLICITY ABB Product Screen brings smart-phone logic to its robot-controller device, the FlexPendant.

The software package uses graphical objects, known as widgets, to perform basic robot functions. Widgets can be created using either ABB ScreenMaker or third-party software such as Microsoft Visual Studio.

The software’s on-screen customisation and user-friendly navigation are designed for use with a variety of applications such as arc welding, spot welding and dispensing. Widgets can be programmed to perform information, control, monitoring and notification functions. Users choose which widgets they need as well as what they should look like. Ready-made widgets and apps also can be shared and downloaded from ABB’s application library, Robot Apps.

The purpose of Product Screen is to bring about a cost-effective way for robot operators to interact with the robot directly from the FlexPendant. Its production environment puts the operator in control by bringing only the relevant functions to the forefront, which allows robot operators to focus on production-related data and to work more effectively.

ScreenMaker is a software package, available from ABB, which allows users to create customised FlexPendant GUIs. It eliminates the need to learn the visual studio development environment and .NET programming.

ABB Australia Pty Ltd 180wx135 ensure 10/9/13 AM Page 1 Contact info and more items like this at11:31 wf.net.au/V214

ENSURE MEAT & POULTRY SAFETY WITH SPRAYING SYSTEMS CO All processors have common goals – to ensure the highest level of food safety possible, optimise production and reduce costs.

Whether you’re bagging whole products, packaging linked or formed items, fresh meats, packaged poultry or sliced products, the AutoJet® Antimicrobial Spray System helps processors achieve this outcome.

The system has a proven track record of effectively controlling pathogens including E.coli, Salmonella and Listeria monocytogenes, while reducing operating costs.

IT BOASTS: Closed loop control and precise application Flexibility with varying shot sizes and time intervals Simplified validation process Easily integrated into existing lines Easy clean-up

Spraying Systems Co.

PTY LTD

7 Sara Grove, Tottenham 3012 Victoria • Ph: (03) 8378 4100 • Fax: (03) 9315 3223 • sales@spray.com.au • www.spray.com

Talk to Spraying Systems about your processing requirements, they’re the experts in hygiene and sanitation for food processing.

Serious Spray – Serious Results www.ProcessOnline.com.au

NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 39

NEW PRODUCTS

INFRARED CAMERAS Fluke has introduced the Ti200, Ti300 and Ti400 infrared cameras with advanced connectivity and accuracy to maximise technicians’ productivity in the field. The cameras feature LaserSharp Auto Focus, which uses a laser to pinpoint exactly where the camera should focus for precisely focused images every time.

The rugged cameras connect to the company’s CNX wireless system, letting them be used as a main unit to view live measurements of up to five wireless modules (such as AC current or voltage modules) on screen and integrate the data into the infrared image.

The infrared cameras feature wireless connectivity to easily transfer images from the cameras directly to PCs, an iPad or iPhone which can then be imported into Fluke SmartView software for optimising and analysing infrared images and producing professional reports.

The infrared cameras feature the company’s IR-Fusion technology, which merges the infrared and visual images into a single view to better discover, diagnose and communicate problems. With the technology, images can be viewed from full infrared to blended views to a full visible image, to precisely document problem areas.

The infrared cameras are Bluetooth ready and include wireless connectivity to PCs, GPS positioning and recording, streaming video, ruggedised capacitive touch screen for quick menu navigation, IR-PhotoNotes annotation system, field-changeable rechargeable smart batteries with charge-level indicators and high temperature measurements up to 1200°C (Ti400 model).

Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/V295

ROTARY ACTUATOR Exlar has expanded its SL Series rotary motors and gearmotors with a 75 mm frame size.

With torque to 4.1 Nm continuous and 8.25 Nm peak, the 75 mm delivers a small package with high power.

The improved torque performance of the SL Series motor is the result of the company’s T-LAM segmented motor stator design, where each segment contains individual phase wiring, thus limiting heat generation. Certifications for the SL Series motors include UL, CE and CSA Class I, Division 2. Six frame sizes are available in the series: 60, 75, 90, 115, 142 and 180 mm frames.

The series motors and gearmotors are suitable for use in many demanding applications, including automatic tool changers, dispensing, wire guiding, chip and wafer handling, robot manipulation, testing, web guidance, indexing material cutting, tension control, volumetric pumps, simulation testing, automated assembly, injection moulding and riveting, joining and fastening.

Applied Automation Contact info and more items like this at wf.net.au/V290

40 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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NEW PRODUCTS

CONTAINERISED VALVE TEST BENCH Nessco Pressure Systems (NPS) has developed a containerised pressure relief valve test bench that is suited to the oil and gas industry. The unit, commissioned

by APTS, is one of the first portable testing systems built in Western Australia.

Capable of testing valves up to pressures of 10,000 psi hydrostatically, or with nitrogen gas, the container has been designed to comply with ATEX and Zone 2 fire and explosion specifications, and is DNV rated for oil and gas platforms.

The container can be 100% custom engineered to meet user requirements and specifications, supplying an efficient and mobile service to the oil and gas industry that can be transported directly to on-site platforms for valve testing and certification.

The test bench is equipped with a 100 tonne clamping fixture, allowing valves to be secured efficiently and easily. The facility also contains an internally mounted jib crane with a lifting capacity of up to 500 kg, and an externally recessed bulkhead through which compressed air, nitrogen and electrical utilities can be connected.

For repair and service purposes, the container is fitted with a fixed lathe chuck for valve clamping, a stainless steel workbench with fitted vice, and a tool cupboard to accommodate all fittings used during valve testing.

Pneumatics Direct Australia Contact info and more items like this at wf.net.au/V439

HUMAN MACHINE INTERFACE Schneider Electric has announced its Magelis GTO human machine interface panel (HMI), helping users to build state-of-the-art machines and systems that improve operator efficiency while saving time, effort and money.

The screens come with TFT LED backlighting, providing a high-clarity display and energy savings for machines. With embedded serial, ethernet and USB ports, the device allows for easy connectivity to a variety of automation devices, variable speed drives, printers and the new range of plug-and-play USB connected HMI accessories - including USB tower lights, USB biometric switches, USB alarm panels, etc.

Remote monitoring and control can be achieved using the built-in

Wind Energy

Photovoltaics

Communications

Process Industry

Transportation

Security Systems

WebGate function via ethernet or with any IOS or Android mobile device and the new Vijeo Designâ&#x20AC;&#x2122;Air app. The range also comes with a simplified design using the same cut-out as the previous offer, enabling immediate installation when an existing panel requires replacement.

The device is also available in stainless steel conforming to the standard DIN EN1672-2 - suited to pharmaceutical and food and beverage applications. The devices are built to endure harsh environmental conditions, withstanding up to 55°C operating temperature and offering accessories to protect against chemical and oil substances.

The device also complies with certifications: Marine Bridge and Deck, ATEX (Cat 3 certificates) and Class I Div2, for installation in marine or hazardous locations.

Schneider Electric (Aust) Pty Ltd

DEHN Australia EMAIL: info@dehn.com.au WEB: www.dehn.com.au TEL: +61 (03) 8414 8277 PO Box 290, South Melbourne, VIC 3205 Australia Distributors throughout Australia and New Zealand

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NOVEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

AS I SEE IT A.B.N. 22 152 305 336 Head Office

INDUSTRY IS DOING IT TOUGH

Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson

R

ecent feedback from industry leaders paints a picture of a really tough automation, control and instrumentation (ACI) market. Projects in the process industries, certainly mining, have been deferred or mothballed, and the contraction in manufacturing continues. Both the process and manufacturing marketplaces are demonstrating no growth.

As a consequence of the drop in global demand for coal and steel, the uncertainty surrounding the future of the carbon tax and the minerals resources rent tax (MRRT), the mining industry has postponed or cancelled many projects. Lack of direction in government spending on process infrastructure such as water treatment and sewage plant upgrades has resulted in a sharp drop in public projects.

Added to this is the lack of investment locally in new chemical, food, brewing, pharmaceutical plants - much of the investment is offshore. In fact, manufacturing has been decreasing since the GFC recovery in 2010.

The result for the ACI industry is ongoing servicing for maintenance at a bare minimum level, but no growth. Is this situation necessary?

It is no secret that the automobile industry continues to struggle, requiring more and more government support. Most of the pharmaceutical and food packaging industries have offshored, as has our textile business. Even our transport industry is under scrutiny with under-investment in maintenance of tankers, and probably other vehicles as well.

There is an interesting maxim that should be nailed to every plant manager’s door: “less input; more output”. Every plant, both process and manufacturing, should be driving towards reducing inputs - energy, labour, materials, wastage - and increasing outputs in the form of products and services.

This can’t be achieved without investing in innovation. Australian industries need to innovate, modernise to become faster and cheaper, and to deliver the highest quality output. The culture of ‘if it ain’t broke, don’t fix it’, needs to change.

Management needs to accept that to survive in this market in the future will require a ‘disruptive strategy’ - a strategy, like the internet, that radically changes the way things are done.

Workgroups reporting to the board need to be

wnipt@westwick-farrow.com.au

established to explore what new and innovative products, solutions and services are available, and have been tried and tested in other competitive markets.

In process plants it is imperative to understand what is being measured, how accurately and how reliably, and what is not being measured that should be. There are so many new measuring devices, boasting new materials to withstand harsh environments, digital communication (fieldbuses), self-validation (improved accuracy), wireless connectivity (for those hard-to-cable installations), that can provide more measurement information to help optimise the processes. This data can then be processed faster and more reliably by the next generation of software, PLCs and DCSs, using smart valves, actuators, VSDs to manage each process.

But there is no gain without pain. Implementing a culture of change requires leadership from management, capital investment approved by the board, investment in technician training, collaboration with the vendors and a strong will to innovate.

The IICA can play a significant part in this innovation by ensuring that all practitioners are certified and graded, and that the appropriate training courses are accredited. It is not beyond the realms of imagination that these ‘disruptive strategies’ around innovation create a demand for locally qualified engineers and technicians, and that our universities and TAFEs can profitably train the necessary skilled people.

If we don’t adopt new technologies soon, we will end up selling our resources and importing our skills and finished products.

John Immelman was formerly managing director at Endress+Hauser Australia and was responsible for establishing the Australian operation in 2001. John is the current chairman of the IICA Sydney Branch, an involved member of Engineers Australia, a member of the Institute of Directors and the founder and former president of the Profibus Association Australia.

42 WHAT'S NEW IN PROCESS TECHNOLOGY - NOVEMBER 2013

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