What’s New in Process Technology Nov 2014 by Westwick-Farrow Media

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ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY NOVEMBER 2014

CONTENTS

Specialising in anti-surge solutions for ship loading and large gasoline, diesel and crude

larm management - a phased A approach

oil pipelines (along with other fuel derivatives),

New products

gas producers.

Hot products online

ptimising clean-in-place processes O in food and beverage operations Part 2

Mankenberg has developed pipeline protection solutions for many of the worldâ&#x20AC;&#x2122;s largest oil and Available in a wide range of materials, the Model UV6.2 is designed for ambient, cryogenic and high temperature liquid applications (up to 130Â°C) and for high pressure duties that require fail-safe operation, with the capability for remote set-point adjustment. They are vacuum resistant, also be-

As I see it

IICA and the future of manufacturing

ing suitable for dry running systems. At the control unit (closing piston) the inlet pressure is in balance with the valve spring force (set value). If the inlet pressure rises above the set value, the valve opens (in the pilot valve or in the inner chamber of the main valve). With the inlet pressure falling, the valve closes driven by the spring tension and the increasing pressure downstream of the closing piston. In a depressurised line, the valve remains closed. The direct acting type has a preset response pressure, while the pilot-controlled type offers adjustment of the response pressure and closing time. Face-to-face dimensions, process connections and materials can be customised to meet any requirements (including DUPLEX, Hastelloy C and 316LSS) and installation in both horizontal and vertical pipelines is possible. A manual operating device (MOD) provides for function

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control, bleeding and flushing if required, and options such as an exchangeable filter for the pilot system and a contamination level indicator for the pilot system provide for preventive maintenance. Powerflo Solutions Pty Ltd www.powerflo.com.au

ALARM MANAGEMENT A PHASED APPROACH

Tyron Vardy, Alarm Management Consultant, Honeywell Process Solutions

Poor alarm management can lead to serious consequences in process plants. The integrity and effectiveness of alarm management can be crucial in either assisting the operator by indicating abnormal situations quickly and simply, or otherwise by distracting, confusing or failing to notify the operator of abnormal situations. • Increased production and throughput • Reduced maintenance and asset availability There is also evidence to show that measurable benefits from alarm management can be achieved. Honeywell’s own research suggests plants can, on average, cut in half both the unplanned downtime as well as the number and cost of incidents with an effectively executed alarm management program. Other observed benefits include as much as 3% increased capacity utilisation, 5% better energy utilisation and a 5% improvement in mechanical availability. What these figures suggest is that the primary goal of alarm management is not to reduce the number of alarms. A reduction will occur, but it is the result of a good system put in place to achieve business and operating goals, rather than the aim itself. The quality and clarity of the alarms presented, not the number, is the most important aspect of any alarm management program. Alarm management is a contributor to many business objectives including reliability, productivity or performance, safeguarding the plant and reducing costs. Something that is often talked about in Australia is the challenge of an ageing population, and therefore a workforce where the skills gap between retirees and the next generation is on the increase. An effective alarm management system will capture the knowledge of experienced staff, file the causes, consequences and corrective actions for each alarm, and retain this information for the benefit of less experienced operators. The key to developing an effective alarm management strategy is to firstly understand why it is being developed and the different requirements that will drive the solutions.

he process industry is not the only sector that understands the importance of alarm management. In April 2013, a United States notfor-profit organisation, The Joint Commission, responsible for accrediting hospitals, warned that doctors were increasingly desensitised, immune or overwhelmed by constant hospital medical alarms - what researchers labelled ‘alarm fatigue’. Between January 2005 and June 2010, the US Food and Drug Administration’s Manufacturer and the User Facility Device Experience database revealed that 566 alarm-related patient deaths were reported. It was found that physicians were prone to turn down alarm volumes, turn them off or adjust the alarm settings outside safe parameters, resulting in these serious and fatal consequences. Alarm management in the process industry has been dictated by and restricted to the capabilities and functions of specific tools or local site knowledge. Investment in software tools can do little to resolve underlying problems if the results and findings are not actioned in a structured and timely way. Even where process companies take a wider view to include software tools, formal standards and procedures, a framework to tie these elements together is usually lacking. It is important for the process company to be clear about the reasons to undertake an alarm management project. These will vary between businesses, but without a clear agreement on the benefits sought, it is impossible to tailor an effective program to the organisation’s needs. There are a number of common drivers for embarking on an alarm management journey: • Regulatory compliance • Safety improvement and operating efficiency • Insurance premiums • Reduction of trips

Alarm management

Program ingredients

Human factors Human factors are crucial to effective alarm management. No system can be effective, regardless of how technologically advanced it may be, without the human component. Established best practice and research should inform every step within the program. If we know that it takes, on average, one to two minutes for an operator to read an alarm, understand the consequences and take corrective action, then there is little point in presenting them with multiple critical alarms in a short time period (or alarm flood). How do you prioritise the emergencies in an alarm system that relies on alerting an operator with two emergency alarms at the same time? Operators should be engaged at every stage of the improvement plan to capture their knowledge and gain insight into human limitations. This also helps employees to adapt to, and understand, the alarm program. Alarm management improvement is achieved through a phased approached. The two phases that have the largest impact on the program are the identification and elimination of bad actors and alarm rationalisation. As each phase is successfully accomplished, the overall number of daily alarms will reduce, as will the alarm floods

Alarm management: Metrics and Reporting softrware

Safety

Reliability

Alarm management: Master Alarm Database

Efficiency

Sustainability

Figure 1: Alarm management methodology.

alarms/day

Techniques, standards, tools and best practices all play a role in alarm management. Most plants will be familiar with, and already have, a range of these. There is not one specific action for a desired result; instead, operators should pursue a combination of actions that will make a positive and strong impact. The alarm management program provides the framework to apply the various contributors in a coordinated and logical way to achieve the business goals (Figure 1). It allows lessons learned in one area of a plant or facility to be captured and applied to another area. It also promotes a resilient strategy by building alarm management around a program rather than a specific tool, process or workflow. The strategy is never undermined.

Phase 1: Infrastructure Phase 2: Identify and Eliminate Bad Actors Phase 3: Alarm Flood Analysis

Phase 4: Alarm Rationalisation Phase 5: Abnormal Situation Management

Figure 2: Alarm management is a continual process.

Identification and elimination of bad actors This phase should focus on the areas of biggest risk and greatest returns, while generating compliant key performance indicator (KPI) reports that meet business deliverables. We need to focus on addressing the problem alarms as they occur so that the facility can stay within its KPIs. The software tools should be easy to use and generate web-based, KPI reports that provide a snapshot of current alarm system performance. Reporting on KPI metrics is only one part of the solution - improvement comes from the action taken on the information provided by these metrics. To drive improvement in this phase, action clearly needs to be taken. ‘Bad actors’ can range from faulty transmitters to inadequate on/ off delays, leading to repeat offenders and those chattering alarms. These provide unnecessary ‘noise’ and ‘fog’ for the operator.

We can start the improvement plan by simply identifying the top three alarms each week, engage with Maintenance and Operations to have these problems addressed and then build this weekly process into the workflow of the organisation to provide ownership and continued delivery of the improvement plan. With this process, it is possible to achieve an 80% reduction in overall alarms.

Alarm rationalisation Alarm rationalisation is misunderstood throughout the industry. Effective alarm rationalisation can only take place once the ‘noise’ that is caused by nuisance alarms has been eliminated. It is not about reducing the number of alarms, but rather more about the quality of them. This means we need to confirm the design of the alarm is correct in the first place. The process involves analysing each alarm and looking at its cause, potential

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Alarm management

consequences and any corrective actions that are required. If there is no operator action that needs to be taken, it is not an alarm. In some cases, operator alerts may be beneficial; however, evaluating the need for each is recommended otherwise alerts may become a nuisance also. Alarm rationalisation will include review and approval changes from phase two - these include grouping, cloning and a tag-by-tag review, as well as addressing standing alarms and operating modes, alarm priorities and so on. This should lead to an end-of-assessment review, summary and training, highlighting the changes made and reasons for them. Essentially, we need to determine if the plant alarms have the correct priority, whether operators know what to do and what the actions associated with each alarm are. The purpose of priority is to indicate to the operator which alarm to respond to first when one or more alarms ring in at the same time. This should also follow the guidelines set out in an alarm system

HUMAN FACTORS ARE CRUCIAL TO EFFECTIVE ALARM MANAGEMENT. NO SYSTEM CAN BE EFFECTIVE, REGARDLESS OF HOW TECHNOLOGICALLY ADVANCED IT MAY BE, WITHOUT THE HUMAN COMPONENT.

design document - the alarm philosophy document (APD). Consequences and response time will be site specific and detailed in an APD. The APD should dictate that the change management process is followed and the knowledge of the rationalisation exercise is captured. If the consequence of the alarm is severe and the time the operator has to respond is less than two minutes, the alarm priority will most likely be critical. Those with minor consequences and a response time of greater than 30 minutes will be of a lower priority. Most importantly, operations need to be rationalised prior to implementation for any additional alarms installed due to new equipment, otherwise all the effort in this

NEW

phase of the alarm management improvement program will be lost.

Conclusion Alarm identification, elimination of bad actors and alarm rationalisation will have a positive impact on the alarm rate and improve the overall performance of the alarm system. Software tools are key enablers to managing, monitoring and maintaining the alarm system. Using the tools continuously will guarantee long-term success of the alarm system and an improvement in the operatorsâ&#x20AC;&#x2122; reactions to alarms. Honeywell Process Solutions www.honeywell.com.au

LINEAR POSITION SENSORS The LR Series non-contact linear inductive

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sensors have been developed to fill a gap in the factory automation marketplace. Presently most factory automation applications are solved with linear potentiometers,

PHOTOELECTRIC SENSORS The latest O6 type photoelectric sensors from ifm efector now also come in a stable plastic housing. The robust diffuse reflection sensor features a particularly reliable background interference suppression. The setting ranges via potentiometer and a rotary switch is intuitive and simple (light-on/dark-on selection). The sensing range is independent of the colour of the object being detected. Even highly reflective backgrounds like stainless steel as well as moving machine parts do not affect the background suppression. The clearly defined round light spot in the operating area ensures consistent light distribution in the light cone. Scattered light around the light spot which could potentially disturb other photoelectric sensors reflection is completely avoided, providing additional safety. This compact unit (13 x 41 x 21 mm) offers variants with PUR connection cable, M12 pigtail or a robust M8 metal connector on the housing. The sensors are also available as through-beam and retroreflective systems. ifm efector pty ltd www.ifmefector.com

typically due to the higher cost of other available advanced technologies. Bestech says the LR Series inductive sensors offer non-contact measurement at a similar cost to potentiometers. They have a good stroke to length ratio compared to LVDTs - they only require about an additional 3.8 cm beyond the stroke. Their zero and full scale are easily field settable, and they can operate on voltages from 5 VDC. The LRx-19 series have a 19 mm diameter and strokes from 25 to 200 mm, while the more heavy-duty nLRx-27 series have a 27 mm diameter and offer stroke lengths from 100 to 450 mm. There are axial or radial connector options and four analog outputs, comprising three voltage and one current output. Bestech Australia Pty Ltd www.bestech.com.au

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TEMPERATURE AND HUMIDITY SENSORS The EYC THS84/85 series of multifunction industrial temperature and humidity sensors has built-in temperature compensation and linear correction. The operating temperature range is from -40 to +120°C for the THS84, and from -40 to +180°C for the THS85. Users can choose from a combination of two different output functions; including relative humidity, absolute humidity, temperature, dew point, frost point, wet bulb temperature, vapour pressure, mixture ratio or specific enthalpy. There is also a programmable version with a Modbus RS485 output. Standard output signal options include 4-20 mA, 0-10 V and 0-5 V as Ergonomic design ensures the meters fit comfortably in one hand. Each key on the clearly organised user interface comes with a secure pressure point. The meters can therefore be operated intuitively with a left or right thumb while the other hand remains free to hold the electrodes in the medium for which the measurement is done. Back in the office the meter is plugged into the USB port of the PC and the collected data is exported straight to the LIMS or Excel, or can be managed in the company’s tiBase titration software.

well as 0-20 mA and 0-1V. The THS85 has the option of being supplied with a 2 or 5 m fitted cable, or an industry-standard M12 connector. Alternatively, the device can be supplied with a factory-fitted display. The THS84/85 series is suitable for many applications such as monitoring storerooms; agricultural and food production applications; industrial process control; air conditioning and ventilation control; environmental monitoring and control; and temperature and humidity monitoring in hospitals or pharmaceutical applications. ADM Instrument Engineering Group

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PRESSURE TRANSMITTER FOR STEELWORKS The HDA 4800 is a high-precision pressure transmitter specially developed for the measurement demands of steelworks technology. The instrument has a robust sensor cell with a thin-film strain gauge on a stainless steel membrane. It has a high tolerance to ambient temperature changes with a thermal drift for zero point and range of less than ±0.01%FS/°C and an accuracy better than ±0.15%FS. The HDA 4800 EMC characteristics are also claimed to guarantee signal stability during the harshest high-frequency, electromagnetic interference that can be found in steel and rolling mills. Additional protection against humidity and vibrations is achieved by encapsulation. By using a shrink-on sleeve, the sensor is protected against bending. HYDAC International www.hydac.com.au

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Poor control of biofilms creates a range of problems in various industries such as drinking water, wastewater, and water for power generation. Many of the problems occur due to corrosion, odours, clogged valves and filters, and reduced cooling efficiencies. Control of biofilms with biocides is difficult and expensive. Under-use can lead to the problems caused by biofilm formation, and over-use can be costly, and create other problems with corrosion or excessive wastewater generation. To achieve optimum results it is necessary to sample and test to determine when to take action. However, traditional methods can take days to return results. The portable biomass field tester from Promicol can provide a solution to the problems of biofilm control in minutes, without the need for laboratory facilities. Based on ATP bioluminescence, the system can provide a rapid indication of total and viable biomass, which indicates the risk of biofilm formation. The field tester includes a luminometer, shaker and power supply, and fits into a compact, easily transportable case. Extra kits to replace reagents and plastic ware are also available. Biocide usage can now be optimised for better control of biofilms, on site and in real time. Australasian Medical & Scientific Ltd www.amsl.com.au

CASE STUDY

Fast track automation of LPG terminal in Mexico

The facility for receipt, storage and delivery of LPG at Atotonilco is one of the most modern in Mexico. It has a design capacity of 20,000 bpd and caters to 160 tankers a day. The terminal feeds the PEMEX Cactus pipeline, passing within 18 km of the terminal, and this location ensures the delivery of LPG for the central-eastern section of Mexico. The terminal facility must pass strict controls and administrative standards for quality, safety and environmental protection. The terminal’s main function is the receipt, storage, safety and filling of tankers with LPG. The product is received at a pressure of 20 kg/cm2 and is stored in two areas at ambient room temperature and a pressure of 7 kg/cm2, each with a capacity of approximately 4000 m3. The objectives for the automation project encompassed the following key requirements: 1. The control system should provide safety and flexibility in operation as well as correct and reliable integration with the existing systems of Pemex Gas and Basic Petrochemicals. 2. The safety system must monitor 100% of operations and comply with all environmental and safety requirements to international standards. 3. The implementation must be done in a period not exceeding one week. Best practices for operation and control of the terminal for receipt, storage and delivery added to the list of objectives: • Ensure a filling capacity of 12,500 to 50,000 bpd in the first stage. • Cover the LPG demand in quantity and quality in the centralwestern area of the country. • Achieve operating cycles and life of the facilities to operate for 30 years. The construction of the terminal facility represented a major challenge for the company’s EPC (engineering, procurement and construction) contractor. The project required a comprehensive solution to include the process control system of the terminal (supervision of inventories and filling of tank trucks), as well as the safety instrumented systems of the terminal (emergency stop system and fire and gas system). The project also required an access control system to ensure proper communication with the Pemex administrative system (SAP), and the control and safety systems of the terminal. A team of experts from Emerson Process Management collaborated with the terminal operator from the FEED stage (front end engineering and design) and throughout the project. Emerson’s DeltaV digital automation system, and two DeltaV SIS safety systems, one for the fire and gas system and another for emergency shutdown, where implemented. Emerson installed measurement skids in the custody transfer points and in the terminal itself. Emerson also installed all the instrumentation of the plant, with the exception of the radar level gauges in the spherical storage tanks. The implementation and commissioning of the terminal was performed in 24 hours, after which the plant reached its design capacity of 20,000 bpd, which met the deadlines and expectations of planned production.

The results of the implementation were considered successful. In just eight days after the launch, the capacity was increased by 220%, to load more than 40,000 bpd. The main enabler for achieving this result, according to the experts themselves, was the design flexibility of the plant and the robustness of the operational control system which accommodated significant changes in the production capacity. Another example of the flexibility of the system was the remarkable improvement in the tanker filling time. In plants with the same characteristics, this process may take typically an hour and a half, with an error of up to 50 kg. The Atotonilco terminal conducted this process in half the time, and with error of less than 1 kg, which enabled a filling capacity of up to 160 trucks per day in its 10 filling islands. This represented 40 trucks more per day than similar plants. For the safety system, Emerson’s DeltaV SIS was used, meeting 100% of the international normative and functional safety standards IEC 61508-3 and IEC 61511-1. The fire and gas system of the terminal also uses Emerson’s DeltaV SIS system, which protects the plant in a distributed manner. It allows users to detect the conflict area and act directly on it. The system is connected with fire and gas detectors, and regulates the pressure of water, and controls the start/stop sequence of the main electric pump motor, fire pump and relief pump. The system accurately coordinates between the fire and gas system, the emergency stop system and the process control system, along with the safety measures taken in the plant. The plant has since achieved a milestone of 730 days without an accident (May 2012). “The system is so flexible and reliable that it can operate optimally at all times and also meet seasonal increases in demand,” said the manager of the Atotonilco terminal, Moses Decto. “The plant is 100% controlled by means of a single system that allows us to monitor and control all the variables.” The original version of this article was published in Spanish in Petrotecnia magazine in December 2013. A slightly longer and more detailed version of this article can be read online at www.processonline.com.au/case_studies/70255 Emerson Process Management www.emersonprocess.com.au

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LAYER 3 SWITCH The Hirschmann MSP30 Layer 3 switch offers extensive routing functions and enables communication between physically separated networks. The managed rail switch also supports a wide range of security functions and guarantees all-around protection for the network to ensure maximum productivity for connected systems and machines at all times. The switchâ&#x20AC;&#x2122;s combination of extensive routing and security functions is said to make it a powerful alternative for DIN rail industrial ethernet systems. Due to PoE+ support, terminal equipment can be powered cost effectively straight from the data line, eliminating the need for additional power supply units or extra cables. The Layer 3 switch supports standard redundancy protocols, allowing users to segment networks into subrings, further enhancing its availability. Due to the deviceâ&#x20AC;&#x2122;s ruggedised design, the Layer 3 is suitable for use in harsh conditions near the shop floor where it facilitates direct routing to other production floors without the need for a backbone router. The modular design of the Layer 3 switch provides users with flexibility for both current and future requirements without replacing the entire switch. Also, modules from other switches in the MSP30 family can also be used in the new routing variant. Belden Australia Pty Ltd www.belden.com

NEW PRODUCTS

CONFINED SPACE LINEAR DRIVE The DryLin SLN-27 miniature linear axis from igus with polymer bearings and an optional NEMA 11 certified motor was developed specifically for confined spaces and offers design flexibility for positioning small loads. The DryLin SLN-27 miniature linear axis is based on the DryLin N27 linear guide system. The linear rail of both the N27 and SLN-27 is made of durable anodised aluminium. The plastic carriage has high wear resistance and is maintenancefree, self-lubricating and corrosion resistant, providing a ‘fit and forget’ solution. With compact dimensions of 22 mm high by 28 mm wide, the SLN-27 is suitable for low-load sensor adjustments and feed mechanisms, as well as lightweight handling tasks such as those found in laboratory equipment and camera inspection machinery. The carriage is driven by a 5 mm trapezoidal or high-helix thread lead screw and is available in a range of pitches from 0.8 to 5 mm. The lead screw nuts are made of igus iglide polymers, which are optimised for lubricant-free operation over the entire stroke

Sensor Monitoring Services

length, which can be a maximum of 250 mm. The compact SLN-27 can be bought as a complete system

Industrial Control ZigSense cloud controller is an

Energy Metering

with a NEMA 11 stepper motor. For customers that already

Refrigeration

Tank & Silo Level

have a stepper motor, igus offers a ‘quick-fit’ aluminium spacer

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

and motor flange connection to fit the NEMA 11 motor. Treotham Automation Pty Ltd www.treotham.com.au

Aquaculture

OIL CONDITION SENSOR The LAB 1400 sensors are HYDAC’s latest compact, multifunction sensors for determining the condition of fluids online. The user can be informed immediately of changes in fluid conditions, for example due to oil ageing or contamination so the problem can be resolved accordingly. The basic device has one switching output (for warning or alarm) and one selectable analog output signal (4-20 mA or 0-10 V) from which measured values can be read out in a sequence. The measured values can also be displayed on various HYDAC display units. As well as displaying status via LEDs, the LAB 1400 transmits analog detection of saturation level, temperature, change in conductivity and change in DC, as

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

well as the switching output. HYDAC International www.hydac.com.au

NEW PRODUCTS

PURGE PRESSURISATION SYSTEMS Purge solutions such as the Pepperl+Fuchs 5000 and 6000 Series purge pressurisation system provide the means to operate general-purpose equipment in classified areas or in environments that are highly corrosive or dusty. The principle behind purge and pressurisation systems is to prevent a corrosive, dusty or potentially explosive atmosphere from penetrating a closed protective housing using an overpressure technology. Pepperl+Fuchs now offers local expertise designing and manufacturing solutions that satisfy safety and operational requirements in todayâ&#x20AC;&#x2122;s process automation environments. Rugged construction makes the series suitable for use in applications where corrosive or potentially explosive environments exist, and their advanced and flexible design - as well as universal mounting options - makes the units easy to integrate into existing and customised systems. A user-friendly interface with backlit LCD and highly visible LEDs allows easy access to programming and operation. The manifold has an automatic purging and pressurisation feature that offers considerable cost savings on gas applications using non-atmospheric air. A gravity-free flapper and rotatable vent cap with spark arrestor allow the vent to be mounted in any orientation, even inside the enclosure, while internal flow and pressure sensors detect different rates of purging and pressurisation, providing the ability to have multiple flow rates. Pepperl+Fuchs (Aust) Pty Ltd www.pepperl-fuchs.com

NEW PRODUCTS

ROLLER PINION SYSTEM The Nexen Roller Pinion System (RPS) is claimed some limitations of con-

POWER SUPPLIES FOR EX APPLICATIONS

ventional drive systems

Three power supplies and three DC/DC converters in

such as ball screws, tra-

the Quint Power series from Phoenix Contact are now

ditional rack-and-pinion

approved for use in potentially explosive areas.

to overcome the trouble-

systems and belt drives, and offers higher performance, accurate linear positioning, low backlash and simple installation.

The power supply units with coated PCB are designed for extreme requirements. They conform to standard

There are various grades of RPS available: from Premium

EN 60079-15 and may be used in hazardous areas. IECEx

Grade with accuracy of ±30 µm to the Versa Rack and Value

approval has already been granted: here the devices

Pinion with accuracy of ±500 µm - using a thermoplastic rack

are suitable for use in Class I, Division 2, Groups A to

which is durable for repeatable applications.

D or A to H. Due to the coating, all modules provide

Across industries as varied as laser cutting, machine tools and

optimum protection in extreme ambient conditions such

mining, users will benefit from the accuracy and 99% efficiency

as dust, corrosive gases or 100% humidity. The single-

of the Premium Grade technology, while the Versa Thermoplastic

phase power supplies are designed for 24 VDC output

Rack and Value Pinion can accommodate the lesser accurate

voltage and currents of 5, 10, and 20 A. The DC/DC

applications with a more economical price point.

converters provide a constant voltage of 18-32 VDC with

The performance of the RPS is due to the pinion consisting

output currents of 5, 10, and 20 A.

of bearing-supported rollers that engage a unique tooth profile.

For maximum availability of the connected loads, SFB

Two or more rollers engage the teeth in opposition at all times

(selective fuse breaking) technology ensures reliable trip-

to eliminate backlash. The pinion rollers glide easily along a

ping of circuit breakers. Faulty current paths are thereby

tangent path and roll smoothly down the face for quiet, low-

switched off selectively, the fault is located immediately,

friction operation up to 11 m/s.

and important system parts remain in operation. For

The Nexen RPS system has six different rack models and two

magnetic tripping of circuit breakers, the 20 A modules

pinion types, and is also available in precision ring drives and

supply a peak current of 120 A for 12 ms, for example.

roller pinion gear systems.

Preventive function monitoring of voltage and current are

Norman G Clark Pty Ltd

passed to the controller via the active switching output

www.ngclark.com.au

or the floating relay contact. Phoenix Contact Pty Ltd www.phoenixcontact.com.au

NEW PRODUCTS

REMOTE MANAGEMENT SERVICES HMS Industrial Networks has expanded the Netbiter Remote Management offering to include three different services catering for different user needs. The dedicated services enable both quick connection to a single remote machine, as well as advanced projects including multiple installations and users. Netbiter is a cloud-based solution for remote management of equipment such as power generators, PLCs, sensors, tanks, etc. Users connect a Netbiter gateway to their equipment and log in to the Netbiter Argos online data centre (www.netbiter.net), where they can access their devices online. Netbiter now includes three different services. The included Remote Access service opens up a secure tunnel to a PLC or machine, enabling configuration, programming or debugging of almost any industrial device from any location. Users use their regular configuration software just as they would if they were on site. The included View and Control service allows users to manage a single installation remotely. Online dashboards, alarms and trend graphs provide full insight from any location. The subscription-based Manage and Analyze service is designed for large-scale, multiple installations with several users. Users can customise the Netbiter Argos interface and integrate data into their own system with the Netbiter Argos API. HMS is also offering the Netbiter EC310 gateway, which sends data from the remote site via ethernet only. This is a complement to the EC350 which communicates both via the mobile phone network (3G/GPRS) and via ethernet. Global Automation Asia-Pacific www.globalautomation.com.au

Ari vAlves… protect you, your plAnt And our plAnet.

NEW PRODUCTS

RADIO REMOTE CONTROL RANGE The SAFIR range of radio remote controls from Jay Electronique consists of two families of handheld controls, ‘Beta’ and ‘Gama’, and two Bellybox families, ‘Pika’ and ‘Moka’. All

ARI ‘FABA’ Bellow Sealed Globe Valves for Oil & Gas and Industrial applications. Double wall bellow sealed stem ensures ZERO leakage. Ideal for steam, hot water, chemicals, air, gases and thermal oil. Available as dual function check & stop valve. In cast iron, SG iron & cast, forged or stainless steel.

of these families can be configured to offer varying combinations of buttons, switches or joysticks to meet the needs of the application. Standard on all SAFIR transceivers is a backlit, anti-reflection, LCD display able to indicate the battery charge level, the behaviour of the radio link, the name of the equipment being controlled remotely and feedback from the equipment such as weight of load, overload, limit switches, alarms or fault diagnostics. Navigation menus also allow users to configure the application, integrate a large number of functions or monitor a specific part of the equipment. Further customisation of logos and pictograms which appear on the screen is also available utilising the iDialog software supplied with each unit. Safety is at the heart of the SAFIR product range with the emergency stop function certified SIL 3 (EN 61508) or PLe (EN 13849) and the standard function buttons, certified to SIL2 or PLd. Other options are available to enhance the safety of those applications that require it, such as infrared startup, action zone limitation, validation buttons or use in ATEX areas. Access to the radio remote control and certain functions can also be limited to authorised operators by password. Control Logic Pty Ltd www.control-logic.com.au

ARI fABA Bellow seAl gloBe vAlves DIN and ANSI dimensions. Straight, Y Form, Right Angle. Flanged and Butt Weld ends.

ETHERNET I/O MODULES The ICP DAS tPET-PD2POR2 and tET-PD2POR2 are compact Ethernet I/O modules with PoE and 2-channel dry-contact digital input and 2-channel Form-A PhotoMos relay output. The tET/tPET-PD2POR2 is an IP-based

Large range of safety and process vaLves in stock for immediate deLivery. austraLian agent & stockist

Ethernet I/O monitoring and control module which can be remotely controlled through a 10/100 Mbps Ethernet network using the Modbus TCP protocol. The tET/tPET-PD2POR2 can be used to create DI-to-DO pair connections through an Ethernet network. Once configuration is complete, the tET/tPET-PD2POR2 module can automatically poll the status of the local DI channels and then write the data to a remote DO device in the background using the Modbus/TCP protocol. They offer low power consumption and include a dual-watchdog with configurable power-on and safe values. Web configuration and firmware updates can be performed via the Ethernet port, and there is also a built-in web server for

Tel: (03) 9699 7355 www.pressureandsafetysystems.com.au 9193p&ss-Wnipt2

configuration. ICP Electronics Australia Pty Ltd www.icp-australia.com.au

NEW PRODUCTS

VALVE ACTUATOR FOR LPG SERVICE Emerson Process Management has released the Fisher P700 rotarystyle actuator for use with Fisher C series internal valves in LP gas services. The actuators offer a reliable method to remotely operate internal valves on storage tanks, bobtail route trucks, and bulk transports. The actuators assure efficient performance of both the actuator and the Fisher C series internal valve to deliver full valve capacity. It is designed to precisely actuate Fisher internal valves and eliminate side-load wear. The P700 series minimises actuator air consumption while maximising service life. The rotary actuators provide easy installation, durable construction, and reliable performance. The actuators are compatible with air, nitrogen, or propane vapour. They include a ¼″ UL-approved thermal fuse plug to provide shut off in the event of an emergency situation and feature a maximum allowable inlet pressure of 125 psig. Emerson Process Management www.emersonprocess.com.au

802.11N WLAN SOLUTION Moxa’s AWK-1131A is an 802.11n wireless AP/ client that features a smaller housing with advanced protection technology, making continuous wireless connections a reality for industrial applications. It is designed with galvanic isolation technology to protect devices from the electrical disturbances commonly found in industrial environments. In addition, it supports 802.11n MIMO technology to reduce multipath effects and increase data rates up to 300 Mbps for bandwidth-hungry applications, and features millisecond-level roaming to minimise packet loss for seamless connections with mobile applications. The 802.11n technology used in the series is suitable for video surveillance applications that require up to a 300 Mbps data rate and Gigabit wired transmissions. With the release of the series, the company now offers a comprehensive range with both single-radio and dual-radio IEEE 802.11n industrial wireless solutions for the bandwidthhungry systems found in industrial applications. Madison Technologies www.madisontech.com

NEW PRODUCTS

PORTABLE MULTIFUNCTION CALIBRATOR GE Measurement & Control has announced the DPI 620 Genii that combines comprehensive, multifunctional test and calibration capabilities with digital HART and Foundation fieldbus communication in a single handheld device. The device integrates with calibration and maintenance software, so that calibration and configuration data is available from the field devices through to ERP. The device is designed for use in the process, chemical, petrochemical, oil and gas, pharmaceutical and power-generation sectors. The DPI 620 can measure and simulate the electrical parameters, temperatures and frequencies that are associated with the majority of process instrumentation. A modular tool, its duties can be expanded by the addition of a flexible pressure system. This comprises a range of 32 high-accuracy pressure measurement modules with ranges from 25 mbar up to 1000 bar; three pressure-generating stations so that pressure can be generated pneumatically from 95% vacuum up to 20 to 100 bar, and hydraulically up to 1000 bar, which solves the transportation and EHS issues of using gas bottles and regulators. The HART and Fieldbus communication capabilities allow configuration, commissioning and calibration of digital devices. With built-in libraries of all 1300 registered HART and 600 Foundation fieldbus device descriptions, Genii can view, change, clone and store device configurations, even offline. Analog variables can be measured and sourced without the need for secondary calibration equipment and Genii provides its own 24 V loop supply and contains an integral 250 ohm HART resistor. GE Measurement & Control www.ge-mcs.com

The best for your RO-System Intelligent, modular solutions for monitoring and controlling the reverse osmosis process

RO monitoring is made easy with Bürkert’s 8619 MultiCELL controller, which can monitor pressure, flow, pH, ORP, Chlorine, conductivity, as well as mathematical logic. Now with field mount enclosure. Contact Bürkert now. 1300 888 868 | sales.au@burkert.com Water RO systems HP.indd 1

27/10/2014 1:03:45 PM

NEW PRODUCTS

LED STROBOSCOPE Due to its 200 high-performance LEDs the Rheintacho Strobe 7000 LED offers powerful light intensity. The large,

IMAGING IR THERMOMETER FLIR Systems has announced the TG165 imaging IR thermometer, a powerful, affordable, compact tool that lets users see invisible heat patterns, measure temperatures accurately, and conveniently store images and

homogeneous illumination surface delivers high

measurement data for reporting.

illumination even in difficult light conditions, making it

Built around the companyâ&#x20AC;&#x2122;s Lepton micro

suitable for a very wide range of measurement, observa-

thermal imaging camera core, the imaging IR

tion and inspection functions. It is especially suitable for

thermometer eliminates the blind guesswork

demanding applications, such as those in the printing industry. With an adjustable flash duration and adjustable light intensity, the LED will easily find the most optimal setting for sharp images at every application. The stroboscope can be controlled directly by the trigger signal of the existing system without the need for additional control units or by various external control devices. When using these trigger options simultaneously, it is possible to easily alternate between the signal inputs by using the switch on the reverse side of the stroboscope. With this feature it is also possible to switch to solid light when the machine is at standstill. SI Instruments www.si-instruments.com

of troubleshooting by combining a single spot IR thermometer with a thermal camera in a rugged, compact package that is easy to use. This combination of technologies speeds troubleshooting, making it easy to find invisible hot and cold spots from a safe distance so users can investigate and solve problems quickly. The deviceâ&#x20AC;&#x2122;s dual lasers visually mark the edges of what is being measured and the crosshairs pinpoint the centre point of the measurement area. The thermometer is designed to withstand a two-metre drop, making it rugged enough for industrial professionals. FLIR Systems Australia Pty Ltd www.flir.com.au

Projekt4 14.10.14 11:08 Seite 1

NEW PRODUCTS

3D SOLIDS SCANNERS Emerson Process Management has introduced the Rosemount 5708 Series of 3D Solids Scanners for the continuous measurement of level, volume and mass of bulk solids and powders in large vessels, bins and silos. The 5708 Series uses acoustic measurement and 3D mapping technologies, and is claimed to provide more accurate and reliable results than previous technologies, even when measuring uneven or sloping surfaces under dusty conditions. Rosemount 5708 Series 3D Solids Scanners are designed to provide more accurate measurements of stored contents for improved process and inventory control. Unlike laser-based technologies that can take several hours to take measurements and require the process to be shut down, Rosemount 3D Solids Scanners provide continuous volume measurements that are representative of the materialâ&#x20AC;&#x2122;s surface. They can measure practically any kind of material including difficult-to-measure fly ash and materials with a low dielectric that would challenge other technologies. The self-cleaning design requires low maintenance even when used in the dustiest environments. Rosemount 3D Solids Scanners are suitable for measuring solids in silos, large open bins, bulk solid storage rooms, stockpiles and warehouses. There are models to deliver either level data only or both level and volume data using intuitive monitoring software. The Rosemount 5708 Series includes level scanners for silos up to 5 m diameter and 70 m height, and there is also a version for larger vessels and silos up to 12 m diameter and 70 m height. Emerson can also supply systems of multiple devices to cover large areas such as 30 x 70 m warehouses. Emerson Process Management www.emersonprocess.com.au

270x88mm HACH PACIFIC_ProcTech_Turbs:layout

6/24/14

NEW PRODUCTS

I/O MODULES FOR ROBOT APPLICATIONS Belden will now offer a Quick Connect feature on its Lumberg Automation Input/Output Network-Ruggedized (LioN-R) EtherNet/IP modules. The feature is designed to contribute to faster overall production cycles for

MEASURE TURBIDITY WITH CONFIDENCE.

industrial applications where robots drive the automation process. The Quick Connect feature ensures that the modules in the LioN-R series can quickly and efficiently power up and join an EtherNet/IP network after a tool exchange on a robot has been performed - reducing the time it takes for the automatic tool changers (ATCs) found on modern robots to exchange tools and switch out the task the robot performs. Typically the powering up operation can take from 5 to 8 s, but it is claimed that with the Quick Connect technology a robot can return to work after a tool change in less than 500 ms. Minimised ATC changeover time allows industrial organisations to adjust robots to serve multiple purposes. This reduces the number of robots needed, minimising maintenance requirements and production cycle downtime. Other features of the LioN-R EtherNet/IP include an IP67 degree of protection, M12 connection for the network, integrated dual-port switch to facilitate line and ring topologies, three modules providing flexibility, a fail-safe function and an operating temperature range of -10 to +60°C. Belden Australia Pty Ltd www.belden.com

Hach has a wide range of turbidimeters that can be suitable for any application. • Raw Water • Filtered Water

SIGNAL CONDITIONERS Five signal conditioners from the Mini Analog product range from Phoenix Contact are now listed according to ANSI ISA 12.12.01 for the USA and Canada and can therefore be used worldwide in potentially explosive areas of Class I, Division 2. Products include two highly functional temperature transducers for resistance thermometers and thermocouples, a frequency

• Filter Optimization • Membrane Compliance Contact us to find out which turbidimeter is suitable for your application.

transducer, a power terminal block and a fault signalling module for group error. The two temperature transducers for resistance thermometers and thermocouples ensure that the sensors conform to international standards. The frequency transducer converts speed pulses from

AU: 1300 887 735 | hachpacific.com.au NZ: 0800 50 55 66 | hachpacific.co.nz

under 1 Hz up to 80 kHz into an analog signal. The module can be operated with Namur sensors or with NPN/PNP outputs. The fault signalling module offers clear error evaluation in multichannel applications with up to 80 modules. With the addition of the power terminal block, it is also possible to detect and indicate the failure of a supply voltage. Phoenix Contact Pty Ltd www.phoenixcontact.com.au

6:56 AM

OPTIMISING CLEAN-IN-PLACE PROCESSES IN FOOD AND BEVERAGE OPERATIONS PART 2 Benjamin Jude and Eric Lemaire*

Existing clean-in-place (CIP) processes are time intensive and waste large amounts of energy, water and chemicals. In Part 1 of this article the risks and costs associated with inefficient CIP processes were discussed, but new innovations in CIP technology can now allow plant operators to cut costs in an environmentally friendly manner while still conforming to regulatory safety standards.

ecent innovations in technology now enable plant operators to calculate the optimal mix of water, chemicals, temperature and flow required to achieve safety standards while saving energy and reducing the downtime for cleaning, as well as providing tracing and documentation.

Optimisation strategy While every food and beverage processing plant’s requirements are different and details will vary, experience has shown the most successful approach for CIP is based on three pillars: • Effective and efficient design • Energy efficiency • Automation optimisation An initial audit of each of these elements helps to identify any existing gaps and can establish an execution roadmap for leveraging efficiency and safety gains.

Efficient and effective design Efficiencies can be gained by introducing smaller, decentralised CIP systems to the plant. This approach reduces the amount of energy required to transport heated chemicals through long pipes to far corners of the production installation. The shorter distances for delivery of detergents, save water, energy and time.1 Multi-use CIP systems can also generate significant water and chemical savings. For example, a dairy processor in Australia had previously utilised a single-use CIP system. In its old system, all the water and chemicals were used once and then discharged to waste. The system was replaced with a multi-use CIP system that recycles the final rinse water for the pre-rinse cycle. All chemicals used in the system are also returned and circulated through holding vats, where temperature and conductivity are monitored and automatically adjusted to meet specifications. The new CIP system saved the company AU$40,000 per year with a payback period of only one year.2

Automation

are not set up correctly, fresh water can enter the caustic soda tank, lowering its temperature. In order to return the caustic soda tank to proper operational temperature, some steam (and therefore energy) will be need to be used.

Automation optimisation

Improvements such as repairing leaks, removing dead legs (stagnant water in pipes that could grow bacteria), installing selfpriming pumps to avoid cavitation issues (bubbles or voids, caused by changes in pressure that can lead to early pump wear) and replacing static spray balls with rotating ones for tank cleaning can lead to significant water savings and improved productivity.

Energy efficiencies Up to 30% in energy savings can be gained by making improvements to inefficient, outdated equipment components that waste electricity and by modifying wasteful business processes. Examples include introducing variable speed drives rather than fixed speed drives so that operators can specify the flow rate within the recipe parameters. On the process side, adjustments can be made by better balancing rinsing time to rinsing volume. Energy efficiencies can also be gained from a better managed heating and chemical sorting process (ie, the transition phases from water to chemical, and from chemical to water). Software monitoring will prevent fresh water from infiltrating the chemical tank which then avoids having to reheat the chemical tank. For example, the fresh water should be maintained at a temperature of 10-15°C and the caustic soda tank temperature should be maintained at around 80°C. If the PLCs that manage the CIP

Controls, sensors and alarms are all elements of automation that enable dashboards to be implemented and key performance indicators (KPIs) to be set. Typical KPIs may include cubic metres of water per number of CIPs, water re-use percentage, energy consumed per tonne of product or kilograms of wastewater generated per kilolitre of product.3 Automation improves the quality of information available and allows tighter control of the various parts of the cleaning process (such as creating parameters around the opening and closing of valves and pump operation). It is important that the automation architecture is open; this enables the CIP processing equipment to communicate with other process equipment such as tanks or pasteurisers. Integrated ‘status check’ ability streamlines the efficiency of the operation. An efficient cleaning recipe is based on four key parameters (sometimes referred to as the ‘4T rule’). The process automation system monitors and verifies these four fundamental parameters. By using software to calculate the optimal combination of each parameter, a dramatic reduction in costs can be achieved. The four ‘Ts’ are defined as follows: • Time - Duration of the cleaning cycles • Temperature - The temperature of the cleaning products • Titre - The concentration of the cleaning products • Turbulence - The speed and impact of liquids projected by cleaning products that need to be generated to perform the cleaning task (1.5 m/s minimum speed) A good analogy for understanding how the 4T rule works is to compare the process to a human washing greasy hands. Grease on skin needs a particular amount of soap or detergent to remove the grease (titre). In addition, the water needs to be hot enough to react with the grease and detergent (temperature). The hands need to be rubbed together (turbulence) for long enough (time) to be completely clean. If any one of these elements is not quite right, eg, not enough soap, the water is cold or the hands are not washed for long enough, then the hands won’t get clean. In addition to cleaning recipes, system optimisation also hinges on the design and interconnectivity of the pipework, valves, pumps, instrumentation and PLCs. This infrastructure enables the software to communicate within the system. An expert with knowledge of process and instrumentation drawings (PIDs), automation software, as well as food and beverage industry cleaning applications, can simplify the planning, design and operational deployment process. A PLC/SCADA application with dedicated library for CIP enables an operator to have full visibility over the automation system, and to deploy the correct recipes (implementing the 4T principles) at the right time. Historical data generated by such a system can help to further optimise the operational parameters. The CIP optimisation software can be configured with different cleaning recipes which can be implemented at the push of a button, making plant operation more flexible. Different recipe settings and cleaning parameters can be aligned with specific pieces of equipment.

Automation

The automation software also enables simplified root cause analysis of any issues. The information stored in the library can also be utilised to generate ‘proof of clean’ reports as requested by food safety authorities. System performance efficiency can also be tracked and compared to an established benchmark. If any anomalies are observed, the software can drill down into specific elements or sub-processes of the system to help troubleshoot any issues. For example, an incident was observed recently in an Australian dairy factory. A valve opened to indicate that the cleaning cycle was in progress. To the operators, the system appeared to be functioning properly. The CIP optimisation software discovered later that a pump was not working (therefore, no cleaning fluid had passed through the pipes). The repercussions of not being aware of this problem could have been very serious. However, the problem was averted as the faulty pump was picked up by the automation system report, and the incident was examined in the library to identify the root cause of the problem. Without such a reporting process it is possible that system operators may have realised that a problem existed and re-run the CIP process just to make sure it was clean. However, in this particular instance a re-run would not have helped. Within such a system, it is possible to define which sequence has the best profile according to the 4T rule (this is called a ‘golden CIP ratio’) and then compare this optimal ratio to the actual performance each time a cleaning program is run. If the chemical tanks are displaying an incorrect temperature or an incorrect percentage of chemical (titre), or if the duration (time) is not the same, or if the flow (turbulence) is not the same, the tool will decrease or increase the golden CIP ratio according to the difference. The golden CIP is benchmarked at 100. If the number shows 50 it means that there was a significant problem during the caustic soda or acid phase or both. Within the software windows it is possible to check the detail as to which parameter was not performing according to the weight that has been predefined for each key ‘T’ parameter. It is also possible to track and manage all chemical waste that goes down the drain. If the conductivity meter indicates that it is in a chemical phase and the drain valve is still open, the software tool has a counter showing the volume going down the drain. To manage this volume it is possible to configure a threshold by colour-coding the counter (such as red or yellow) when it reaches this threshold. A final check can be made following the last rinse. The software will indicate a ‘remaining conductivity’ measurement. If this number is high then it means that the final rinse was not well done and that some chemicals are still present in the pipework.

Operational savings An example from a Schneider Electric customer illustrates operational savings gained from an optimised CIP system (see Figure 1)4. In this instance the costs of water, caustic soda and acid were calculated for three months before CIP redesign and for three months afterwards. While the water usage increased slightly as a result of the optimisation, this was more than balanced out by the dramatic reduction in chemical needs. An annual savings of approximately €90,000 was realised without taking into account the increase in production uptime or reduction in energy consumption.

Cleaning the cleaning system Periodically, the cleaning system itself needs to be cleaned. It is important to include this aspect in the CIP design as it requires dedicated pipe and spray balls to be fitted in the CIP tanks. CIP

Figure 1: Monthly costs before and after CIP optimisation. automation software should feature an automatic cleaning recipe that can be activated by the operator at regular intervals. This auto cleaning will remove build-up of cleaning products and residue in the pipework and tanks, therefore enabling the CIP system to operate at maximum efficiency.

Conclusion Food and beverage manufacturers that seek to increase operational efficiency and cut costs should begin by performing an audit of their CIP system to identify areas for improvement. The audit will help determine whether incremental improvements such as balancing out the line capacity or adding a recovery tank to re-use water need to be made. A high level of efficiency can be achieved by addressing CIP design, energy-efficiency improvements and advanced process automation. Such an initiative will result in a positive impact on waste, energy cost, and environmental resource issues. Improved food safety and increased production will benefit both peace of mind and profit margins. Schneider Electric Industry Business www.schneider-electric.com

About the authors Benjamin Jude is a Global Solution Architect/Food & Beverage Vertical Expert at Schneider Electric. For over 20 years he has specialised in automation and process engineering, and has provided turnkey solutions for firms within the food and beverage and pharmaceutical industries. He has particular expertise in process design and electrical control engineering, batch management (MES) and FDA compliance. Eric Lemaire is Food & Beverage Group Marketing Director with Schneider Electric. He holds a degree in Food and Beverage Process Engineering and has more than 20 years’ experience in the process automation industry. He has held many different engineering, R&D, marketing and sales positions, including manager of the French Food and Beverage and Pharmaceutical Industry operations.

References 1. Source: Bulletin of the International Dairy Federation 401/2005. 2. Source: Eco efficiency for the dairy processing industry. 3. Excerpt from Typical key performance indicators for a dairy processor: Eco Efficiency in the Dairy Processing Industry. 4. Data for this graph was taken directly from a report provided by a Schneider Electric customer in France.

NEW PRODUCTS

TEMPERATURE AND DATA LOGGERS The ICP DAS DL-100T Series are logger modules with LCD. The se-

CLOUD-CONNECTED CABLE CERTIFICATION

ries is suitable for a wide range of

Fluke Networks’ LinkWare Live is a service that lets contrac-

applications such as transportation

tors, cable installers and project managers using the Versiv

of food or pharmaceuticals, food

family of certification testers to upload, manage and analyse

and beverage industry, building and

certification test results from cabling projects in the cloud.

IP66 remote temperature and data

energy management, museums, archives and galleries, greenhouse automation and warehouses.

The service works with DSX-5000, OptiFibre Pro, and CertiFibre Pro certification testers to optimise project man-

They contain an RS485 communications interface with DCON or Modbus

agement and safeguard contractor profitability by providing

RTU protocol and an LCD to show a variety of temperature, humidity and

real-time access to testing results, extending support to

module ID data. The data storage memory can store up to 4088 temperature

technicians in the field, and eliminating costly truck rolls

and humidity records. Recording time intervals can be set from 10 seconds

simply for tester transport back to the office. The free

to 1 day and up to 32 modules can be connected on the same bus. Modules

service is available to all Versiv customers.

can be DIN rail or wall mounted.

Collecting certification test results is a significant challenge

Measurement ranges are -20 to +60°C (±0.4°C) and 0-100% RH (±3%RH).

because they are stored in testers that frequently move from

A higher accuracy option is available with ±0.3°C and ±1.8%RH. Modules

one job site to another. These job sites can be hundreds

are IP66 waterproof, powered by 10-30 VDC.

of kilometres away from one another, as well as from

The data logger utility provided with the modules allows installation,

headquarters. Accidentally erased or failed memory cards

configuration, retrieval and display of data in a powerful chart format that

can negate several days’ worth of work, leading to costly

can be exported to Excel.

truck rolls, lowered profit margins and delayed payment.

ICP Electronics Australia Pty Ltd www.icp-australia.com.au

Fluke Networks www.fluke.com

NEW PRODUCTS

RUGGED TABLET PC The RuggON PM-522 IP65 rugged tablet PC meets the MIL-STD-810G rating for shock and vibration and can be dropped from 2 m onto plywood on a concrete surface. It is fully sealed against the ingress of liquid and dust damage and has an operating temperature rating of -20 to +50°C. The 10.4″ LED backlit screen with integrated 10-point capacitive multitouch screen features a display brightness of 700 nits offering sunlight-readable functionality for outdoor applications. The tablet PC is based on Intel’s Atom E3827 1.75 GHz Dual Core CPU and includes 4 GB of DDR3 SODIMM and 64 GB of upgradeable mSATA solid state disk. The hot-swappable dual batteries offer up to 9 h of battery life. A 5 MP webcam with an LED flash and autofocus is embedded in the rear bezel and a 2 MP camera with audio input is in the front panel. Seamless communication is available via the onboard Wi-Fi 802.11 ac/a/b/g/n, Bluetooth 4.0 and GPS plus optional 3.5G or 4G TLE modules. The PM-522 is available with a range of optional data capture options including NFC, barcode scanner, smart card reader (CAC) and magnetic stripe reader (MSR) suitable for portable stock and asset management. Multiple connectivity interfaces include both USB 3.0 and USB 2.0 ports, an audio jack, a Micro SIM slot and an Ethernet port. For user flexibility, two programmable function buttons are located on the front panel. Backplane Systems Technology Pty Ltd www.backplane.com.au

CASE STUDY

Refinery upgrades shut-off valves for improved safety and efficiency

In Europe, safety, efficiency and compliance with European regulations are major criteria in critical applications such as burner management systems. For this reason, one refinery decided to invest in new fuel gas lines and safety systems for its heaters and furnaces to make the units safer and more efficient. Extraordinary reliability is expected from the on-off and safety valves in burner management systems, as unnecessary shutdowns of a heater would cost hundreds of thousands of dollars on a daily basis. In hazardous cases especially, the safety shut-off valves must close under all circumstances. In addition to shut-off safety, the on-off valves in front of the burners are responsible for managing the correct heat temperature. This means that reliable switching is very important as it reduces operational costs and increases the heater efficiency. The refinery’s emphasis on complying with, and even exceeding, the standards for tightness and safety established by the European health, safety and environmental regulations made its valve selection task even more difficult. The company also expected that the chosen valves should be able to perform like new over a long period of time. As shutdowns for inspection and maintenance are costly, regular shutdowns are normally scheduled only once every four years, and they need to be performed as quickly as possible to minimise downtime. Moreover, to protect the health of the operators and the environment, the best possible valve sealing over its full operational lifetime was required to avoid fugitive emissions of hazardous and toxic fuel gases. The refinery chose Metso Jamesbury Series valves for its fuel gas safety shutdown and burner on-off applications. These soft-seated 7000 and 9000 ball valves are made for highly demanding uses such as fuel line emergency shut-off and switching applications. The valves’ seating design and material provide superior longterm bubble tightness that withstands a high number of thermal cycles and valve strokes, even exceeding the 250,000 strokes required by EN 161, which is the standard for automatic shut-off

valves in gas applications. Additionally, the cavity relief feature enables safe operation, even in the event of sudden temperature increases. This allows any fuel gas overpressure that might build up in the ball valves’ cavities to be released automatically on the upstream side. Moreover, the shaft sealing design ensures the highest level of reliability and safety while achieving the lowest possible operational costs. The ball valve series is certified according to the most relevant fugitive emission standards, such as TA-Luft/ VDI 2440 and ISO 15848-1 BH. To fulfil European directives, the refinery followed EN 746-1, the standard for safety requirements in combustion and fuel handling systems, which requires that only EN 161-certified valves can be used in burner management systems. These shut-off valve units are approved by TÜV Rheinland according to EN 161 Class A and certified according to IEC 61508 SIL 3. The approvals include the intelligent safety solenoid with partial stroke testing and diagnostic features that provide additional safety and predictive maintenance capabilities. Since the refinery had all relevant certificates for the fuel gas shut-off valves and therefore fully complied with European regulations, the onsite approval process was accelerated. High process stability and safe operation in the refinery have been achieved through the unique design of these valves created specifically for burner applications. In turn, this has ensured that the operational targets of the process heaters are met according to the planned shutdown schedule. The simple and maintenance-friendly design of the burner valves has reduced operational costs and shortened downtime in the refinery. Additionally, full support has made the implementation of the new valves a smooth process. Original article by Andreas Pischke, who works for Metso as an Area Manager EMEA in the Jamesbury product line. Metso Automation (ANZ) Pty Ltd www.metso.com

NEW PRODUCTS

ON-MACHINE SWITCH The Allen-Bradley ArmorStratix 5700 is an on-machine switch. Built with ruggedised IP67 protection, the Layer 2 managed industrial ethernet switch can be mounted directly onto a machine or application, reducing the overall size and cost of a control cabinet, and shrinking the machine footprint. The managed switch advances connected enterprise

FLUE GAS ANALYSER Emerson Process Management has enhanced the Rosemount Analytical 6888 in-situ flue gas O2 analyser with new diagnostics that help maintain optimum oxygen levels in flue gases, thereby optimising the combustion efficiency of large boilers and industrial furnaces. As plants are struggling under reduced budgets and personnel, the 6888 enhancements help decrease maintenance requirements and improve measurement accuracy. The analyser incorporates a ‘calibration recommended’ diagnostic with gas-switching solenoids embedded within the probe electronics, making automatic calibration easier.

goals by delivering integration of machine-level data that, due to cost or location, would otherwise remain isolated from business-level systems. Using the Cisco IOS network infrastructure software, this switch manages the transfer of production data to enterprise-level databases and information systems for improved decision making. The industrial switch simplifies the design and development of machine-level networks through configuration and monitoring tools. These tools help enable easy set-up and diagnostics from within the Rockwell Automation Integrated Architecture system - bridging the gap between IT and the automation engineer.

The embedded diagnostic reduces the cost of providing and installing a separate solenoid box, and also reduces the effort to wire and pipe between the probe and electronics. Additionally, the ‘calibration recommended’ diagnostic removes the need to conduct calibrations on a schedule. The analyser also includes a ‘plugged diffuser/filter’ diagnostic for applications that have fly ash or other particulate entrained in the flue gases. Another feature of the analyser is a variable insertion option, which permits ideal placement of the probe into the flue gas duct. With standard length probes from 0.5 to 3.65 m in horizontal or vertical installation, the probe can be adjusted at any time online to characterise stratification across large ducts. Easy to use and integrate, the analyser is fully field repairable. All active components can be replaced, including the diffuser/filter, sensing cell, heater and thermocouple, and all electronics cards. The analyser offers HART and Foundation fieldbus digital communications, and can also be configured with the optional Smart Wireless THUM adapter for wireless operation. Emerson Process Management www.emersonprocess.com.au

The Layer 2 switch offers high availability, quality of service (QoS), and automated monitoring to help simplify network optimisation and convergence. The switch comes standard with 8, 16 and 24 fixed-port configurations, and each base model comes with M12 ethernet connectors, SD flash card, dual-power inputs and a panel-mounted design. An expanded switch includes 10 and 18 fixed-port configurations, with two Gigabit ports, hardware-based IEEE 1588, hardware alarms, and up to eight PoE ports. Rockwell Automation Australia www.rockwellautomation.com.au

NEW PRODUCTS

FIXED-MOUNT THERMAL IMAGER FLIR Systems has announced a fixed-mount thermal imager. The FLIR AX8 combines thermal and visible cameras along with the company’s proprietary MSX technology in a compact package, and is easy to install in space-constrained areas for automated and uninterrupted condition monitoring of critical electrical and mechanical equipment. Enabled by the company’s Lepton micro thermal imaging camera core, the AX8 provides early detection of temperature-related issues in electrical and mechanical equipment, guarding against unplanned outages, service interruptions, equipment failure, and fire. The AX8 is a suitable sensing solution for continuous condition monitoring and early fire detection without the need for periodic manual scans. The thermal imager has 4800 active temperature points per image, provides streaming temperature data over industry-standard interfaces (Ethernet/IP and Modbus TCP) for easy analysis, has a built-in web interface, and includes a full suite of analysis and alarm functions that automatically send alerts when the device detects elevated temperatures. Measuring 54 x 25 x 95 mm, the thermal imager integrates easily into electrical installations or any manufacturing environment. The device’s streaming thermal, visual, and MSX video is output in standard MJPEG, MPEG, H.264 formats, adding multipurpose image capabilities. With all of these features in a compact form factor, the thermal imager addresses the condition monitoring and safety needs for many environments, including the process and manufacturing industries; data centres; energy generation and distribution; storage facilities; refrigerated warehouses; and engine rooms. FLIR Systems Australia Pty Ltd www.flir.com.au

NEW PRODUCTS

MANUFACTURING PROCESS AUTOMATION SOLUTION STAINLESS STEEL HYDRAULIC VALVES Rotork Midland manufactures stainless steel hydraulic valves for the offshore oil and gas industry, and has extended its range of products to include wellhead chemical-injection and chemical-dosing applications for offshore well and pipeline installations. The Midland-ACS valve range provides a simple, cost-effective and compact alternative solution to conventional actuated process valves. Manufactured in 316L, super duplex stainless steel and also titanium, the valves are designed for on/off control of a variety of chemicals, such as MEG, corrosion inhibitors, hydrate inhibitors, scale inhibitors and coagulants, as well as sea water, fresh water and hot water. Ex d, Ex e mb solenoid or hydraulic pilot operators enable the valves to operate at pressures up to 690 bar and CVs up to 4.1. Metal-to-metal or metal-to-ceramic seats and a wide range of sealing elastomer materials are available to ensure a tight shut off and compatibility with operating fluids. Exi proximity sensors can be fitted to provide remote open and closed valve position indication.

Infor has announced Infor Factory Track, a comprehensive manufacturing process automation solution that helps manufacturers synchronise their enterprise plans with plant activities; bridging the gap from idea to execution. Built for the Cloud, Infor Factory Track offers flexible deployment options and a lower total cost of ownership. The solution was developed using Infor Mongoose, a rapid application development platform that enables more configurability and ease of enhancements. Infor Factory Track also offers the latest consumer-grade user experience from shop-floor kiosks to handheld barcode scanners. Infor Factory Track will provide a comprehensive solution so manufacturers can increase their operational efficiency and improve visibility across the warehouse and the shop floor. The solution offers three key modules. ‘Warehouse Mobility’ will help organisations simplify inventory management, automate data collection and eliminate errors and inventory write-offs, and also help gain visibility into their material movements and automate both inbound and outbound logistics. ‘Time Track’ will collect labour time and attendance and provide easy payroll extracts to feed payroll applications. Synchronising the workforce with manufacturing activities will allow organisations to increase productivity and control labour costs. ‘Shop Floor’ will help to automate production schedule execution, dispatch operations and work-centre operations. This solution will also enable paperless shop-floor operations to allow greater visibility of the shop floor, increased process control and greater accountability. Infor Global Solutions www.infor.com

Rotork Australia www.rotork.com

DRIVES WITH FUNCTIONAL SAFETY SEW-Eurodrive now offers an integrated S12 safety option for its decentralised Movifit FC/MC drive units, used for constructing modular and flexible conveyor systems. The two option card versions S12A and S12B support different numbers of safety-related inputs and outputs. The S12 option offers the additional safety functions STO (safe torque off), SS1a/c (safe stop 1), SLS (safely limited speed) and SDI (safe direction) on top of the standard Movifit functions. The SLS function can be easily applied using the EI7C/(FS) simple motor-integrated encoder. The safety functions are an integral element of the Movifit modular system. The company’s Movitools MotionStudio engineering software is used to program the S12. The S12 safety option is a cost-effective, integrated safety solution, and it can be used either independently or as a fieldbus slave with Profisafe via Profibus or Profinet. The inputs can also be set as 1- or 2-channel, and they can read OSSD-capable sensors such as light grids and scanners. The safety option is useful wherever materials need moving, such as on roller conveyors, rotary tables and electrified monorail systems for light loads. This is particularly relevant for the intralogistics sector. SEW-Eurodrive Pty Ltd www.sew-eurodrive.com.au

NEW PRODUCTS

COMPACT 1 KW POWER SUPPLY The PULS QS40.241 is a compact 1 kW single-phase, wide input voltage range power supply that has a housing width of only 125 mm and weighs 1.9 kg. In addition to a high efficiency of 94.6% and a low loss performance over a wide range of loads, the power supplies are equipped with PULS ‘HiccupPLUS’ overload protection. This provides well-balanced power management that provides continuous output current repeatedly for 4 s on severe overload and protects mistakenly connected loads and cables against damage until the fault is cleared. The full rated load current is available over the temperature range of -25 to 60°C as well as offering 50% of bonus power to accommodate short-term overloads during normal operation. For easy fuse tripping, the unit provides multiples of the rated output current for 10 ms. The heavy-duty output cable clamps ensure an easy connection of cables with a cross-section of up to 10 mm2 (flexible). The international approval package and the wide input voltage range (100-240 VAC) enable the power supply to be used in applications worldwide. The lightweight QS40 power supply is available with 24 V/40 A, 36 V/26.7 A and 48 V/20 A output. Control Logic Pty Ltd

FIRE-SAFE OPTIC CABLE Helucom FS90 is a range of fire-resistant fibreoptic cable that ensures data communication is upheld for 90 minutes even in the event of a fire. Based on the IEC 60331-25 standard, the cable has been tested for the purposes of function and data transfer under the influence of flames of 750°C for more than 90 minutes. The maximum damping increase was maintained at E9/125 µm 0.12 dB in single mode and G50/125 µm 0.27 dB in multimode. At the same time, the cable range meets the standards IEC 60332-1 and 60332-3, flame resistance, IEC 61034 smoke/gas proof, IEC 60754-2 halogen freedom and EN50267-2-3 corrosiveness. Four different cable types are available: 4 G50/125 µm OM2 (803917), 12 G50/125 µm OM2 (803918), 4 E9/125 µm G652.D (803919) and 12 E9/125 µm G652.D (803920). Treotham Automation Pty Ltd www.treotham.com.au

www.control-logic.com.au

Flexible Modular

Specialist

Design I/O Modules for: • Data Acquisition

• Digital and Analog I/O • Temperature Measurement • Thermocouple and RTD’s • PLC I/O Expansion • Point to Point Multiplexing • Ethernet/Serial Converters • Programmable Logic Controllers

phone:

+61 2 9624 8376

fax:

+61 2 9620 8709

email:

glen@proconel.com

www.proconel.com 35

NEW PRODUCTS

PRESSURE SENSOR The PR3850 pressure transmitter is designed to meet the requirements of industrial pressure measurement applications, where a hygienic flush diaphragm connection is needed. Constructed from stainless steel, its robust design incorporates the latest strain gauge technology, together with a custom IC amplifier giving stability and accuracy over a long service life. This pressure transmitter is particularly suitable for use with high-viscosity materials. Typical applications include food processing, pharmaceutical, petrochemical, and wastewater and slurry handling. The flush membrane is easily cleaned for long-term reliability and performance. The PR3850 gives a stable and accurate output signal of 4-20 mA with options for 0-5 VDC, 0-10 VDC, 0-20 mA and other output signals. A detachable DIN connector is used for the electrical connection, allowing easy access to zero and span adjustment. Pressure ranges available range from 0-4 to 0-400 bar. The standard process connection is 1/2″ BSP, but users can also choose from the optional 1″ BSP and 1/2″ NPT male flush diaphragm process connections. An optional weldable boss is available to ensure flush-face installation of the pressure transmitter to tanks and pipework. An optional IECEx certified version of this pressure transmitter is also available, approved for explosion protection for flammable gases (Zone 0), dusts (Zone 20) and mining areas (Group I M1). ADM Instrument Engineering Group www.admtech.com.au

HIGH-POWER POE SWITCH The Moxa EDS-G512E-8PoE industrial Ethernet switch features a high power output designed for industrial, heavy-duty PoE devices; Gigabit Ethernet capabilities for large bandwidth network transmissions; easy management tools (SmartPoE) for monitoring PDs; and an industrial-grade reliability built to withstand harsh environments. It features eight Gigabit PoE+ ports allowing for large bandwidth transmissions and up to 30 W of power in its standard mode. For heavy-duty PDs (power devices) requiring a higher voltage, the series also allow up to 36 W of power output, ensuring a sufficient power supply for mission-critical, power-sensitive applications. The switch is also designed with a series of management tools that simplify the process of remotely controlling and monitoring powered devices. The tools include a power management function to optimise the system accordingly, and a diagnostic function to detect PD conditions with failure detection and LED indicators. Other features, such as 3 kV LAN surge protection, -40 to 75°C wide temperature tolerance, Turbo Ring and Turbo Chain technology, and Moxa’s industrial network management software, are also included to guarantee network reliability and uptime. Madison Technologies www.madisontech.com

NEW PRODUCTS

CAN AND DEVICENET COMPONENTS WITH DNV APPROVAL Phoenix Contactâ&#x20AC;&#x2122;s infrastruc-

OXYGEN ANALYSER

ture components for data trans-

The XZR400BM oxygen analyser is a small and light transport-

mission via the CANopen and

able instrument, capable of taking readings of both trace and

DeviceNet protocols are now

percentage oxygen levels. It has been introduced to meet the

available with DNV approval. The

demands of companies that wish to take routine readings from

converters, repeaters, segment

multiple sample points. The instrument is capable of taking

couplers and bridges based on

readings on a low flow rate - down to 2 L/h - which means

fibre-optic technology can therefore also be used in shipbuilding and offshore applications. With these components, important requirements such as segmentation, network expansion and electrical isolation can be

less waste of the sample gas from the process. Based on Michellâ&#x20AC;&#x2122;s MSRS zirconia oxygen sensor, the XZR400BM can give readings as fast as 11 s, saving the operator working time when collecting field readings.

implemented. Almost any network structure is therefore possible.

Unlike electrochemical sensors, which require regular replace-

Transmission media such as modem or DSL paths, wireless con-

ment, the MSRS sensor of the device should last in excess

nections or Ethernet networks can be used as an alternative. Even

of seven years. Calibration is needed only every 3-6 months

different data rates in both segments are not a problem.

and can be carried out with just one calibration gas, saving

Fibre-optic technology is used in applications with high demands

time and money.

on availability. Two of the biggest advantages of its use in the

The instrument also features an intuitive touch-screen interface

maritime sector are insensitivity to electromagnetic interference and

to enable fast and easy operation without the need to invest

automatic electrical isolation. This eliminates the need for complex

in extensive training. It also has a switch-mode power supply,

surge protection as well as shielding and equipotential bonding.

operating from mains power 90-264 VAC, and weighs 6 kg.

Phoenix Contact Pty Ltd

AMS Instrumentation & Calibration Pty Ltd

www.phoenixcontact.com.au

www.ams-ic.com.au

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

IICA AND THE FUTURE OF MANUFACTURING

ver the past few years there have been many challenges to our industry - the merging of trades through multiskilling, the emergence of the internet and the reduction in jobs as companies have sought to become more competitive in a shrinking world market. You would expect all this to spell trouble for all industry associations like the IICA; however, I believe the biggest loser for industry associations - and Australia as a whole - is the decline in manufacturing and the slowdown in mining investment. Statistics from the ABS show a decline from over 1,150,000 jobs in 1989 to less than 950,000 at the end of 2013; however, these statistics refer to people rather than jobs. ABS Labour Force Survey Manager Richard Arnett says, “The difference is that there are a lot more jobs than people employed, because people can have more than one job; however, the Labour Force Survey is the best available data, and there would be a close correlation between the two.” In short, people are now doing more than one job due to job convergence and company rationalisation. Associate Professor John Spoehr, executive director of the Australian Workplace Innovation and Social Research Centre at the University of Adelaide, supports this when he says, “There have been considerable manufacturing job loss announcements in Australia within a relatively small timeframe.” He says he expects future ABS data to show an accelerated decline as the manufacturing closures such as Holden, Ford and Toyota bite in the future. When you add to this the mining slowdown caused by fluctuating resource prices and the fact that capital expenditure is expected to dip by two-thirds over the next five years, it is not hard to see that employment levels in the industry are likely to further diminish, and that means worrying times ahead for our members. What the job losses mean to the association is the loss of opportunity for our members and the challenge for us is how

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

we as an association can assist by addressing the issues. Our membership consists of both individuals and corporates, all with a vested interest in the Australian economy. We are offering training for the members, and the opportunity for remote companies to see the latest technology through low-cost exhibitions. While the visitors are low, we see this as very important to both our corporate members and the manufacturing industries in remote Australia, together with an opportunity for members to network and discuss the trends across many business segments. What we are seeking in return from the manufacturing industries is for their companies to recognise the unique skills our members can provide and to consider joining the association - to make us stronger by providing us with better insight into their concerns. In our supplier members we have the technology, know-how and a desire to help Australian manufacturing survive and grow. I see a bright future for the association with our venture into safety training, by facilitating a meeting place for the future by putting suppliers and manufacturers together, and by having influence with the regulatory bodies in determining the best direction for Australian industry. Through technology and partnership, we are working hard to provide all our members with more reasons to join a proactive organisation that has an eye on the future.

Alan Nichols, General Manager of the IICA, began his career in the mid-1960s in the telecommunications industry and has a Certificate in Electrical Engineering. Alan moved to sales and marketing in the late-1970s with Square D and in 1982 joined Honeywell, working with instrumentation. He ran his own distribution business from 1995 to 2007 and now works in business development.

Janette Woodhouse Publisher Geoff Hird Art Director/Production Manager Julie Wright Art/Production Tanya Scarselletti, Odette Boulton Circulation Manager Sue Lavery circulation@westwick-farrow.com.au Copy Control Mitchie Mullins copy@westwick-farrow.com.au Advertising Sales National Sales Manager/NSW/QLD Nicola Fender-Fox ph: 0414 703 780 nfender-fox@westwick-farrow.com.au VIC/SA - Lachlan Rainey ph: 0402 157 167 lrainey@westwick-farrow.com.au WA - Mandy Grubisin ph: 0468 840 739 mgrubisin@westwick-farrow.com.au NZ - Mark Ryu ph: 0800 44 2529 mryu@westwick-farrow.com.au Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application. If you have any queries regarding our privacy policy please email privacy@westwick-farrow.com.au

March 2014 total CAB audited circulation (Aust + NZ) 6,504 readers (76% personally requested)

Contact the editor

Printed and bound by Bluestar Print +61 2 9748 3411 Print Post Approved PP100007403 ISSN No. 0819-5447 All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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