What’s New in Process Technology September 2013

0913

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY SEPTEMBER 2013

CONTENTS 4

Always in touch

Adapting mobile devices to industrial applications

14

Hot products online

8

New products

28

Improve pneumatics performance

Through filtration system design

38

As I see it

TCO: understanding its role in process automation

The FS Functional Safety Series instruments from Moore Industries assist safety engineers with implementing Safety Instrumented Systems (SIS) to prevent or warn of unsafe process conditions. They are designed and built to IEC 61508 standards for functional safety, with independent verification from exida.

These instruments also meet the same high standards of reliability and durability found in all Moore Industries products.

The latest additions are the SSX and SST Safety Isolators and Splitters, which provide reliable isolation and signal conversion for signals associated with an SIS while passing along valuable HART data. The SIL 3 capable SSX and SST family protects safety systems by isolating an SIS from basic process control or monitoring systems so that disconnections or other failures don’t impact the safety system.

The Moore Industries FS Functional Safety Series also offers two other products. The SIL 3 capable STA Safety Trip Alarm is a single loop logic solver that warns and acts on potentially hazardous process conditions, while the SRM Safety Relay Module is a SIL 2 capable relay repeater model that accepts a single contact closure input from a logic solver trip output and provides three additional alarm relay contacts.

For more information on the FS Functional Safety Series, visit www.miinet.com/safetyseries.

Moore Industries Pacific Inc www.miinet.com/au

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ALWAYS IN TOUCH

ADAPTING MOBILE DEVICES TO INDUSTRIAL APPLICATIONS Fredrik Alfredsson, Jonas Bronmark, Elina Vartiainen, Magnus Larsson and Petter Dahlstedt, ABB

4 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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Š iStockphoto.com/michaeljung

Mobile devices have great potential to increase the efficiency, productivity and satisfaction of plant personnel in industrial settings, but despite the obvious gains to be had, mobile devices in industrial settings are not being utilised to their fullest.

T

he potential benefits of using mobile devices in industrial environments are many. Mobile devices could allow people to work more independently; there could be fewer errors as personnel access information on their mobile devices rather than relying on other people or one’s own memory; systems could be updated on the spot; and decision-makers could be contacted directly anytime. Mobility could considerably increase the efficiency of field workers as they could access real-time information away from their work stations or control rooms, enabling greater independence. And yet, despite the obvious gains to be had, mobile devices in industrial settings are not being utilised to their fullest.

Today, mobile devices are an essential part of people’s daily activities, enabling them to keep in contact through calling, texting, emailing and social media. Mobile devices are also used to create media (including photos and videos) that can be shared with others. Moreover, mobile devices are more than just communication devices: they can be used as a music player, a navigation device or a gaming platform, enabling a very powerful combination of technology that can be leveraged for industrial automation. The interaction techniques people use to control mobile devices (for example, touch, voice and gestures) have also evolved at a fast pace during recent years. For example, the introduction of welldesigned, touch-enabled devices changed the smartphone market completely, and voice recognition (for example, Siri on the iPhone) and gesture recognition are finally at an acceptable level. These possibilities enable efficient interaction between the user and the mobile device even in situations where hand/eye interaction is not possible.

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Challenges for mobile devices The challenges of introducing mobile devices in industrial environments include network capability, current work practices, IT infrastructure, environment and safety equipment.

Network capability An industrial plant may not have the necessary network infrastructure for mobile connectivity. This might be quite obvious in an underground mine, where the rock makes it very difficult to build a network that would provide good signal strength. Yet open-pit mines might not have good mobile network coverage either since they are often located in sparsely populated remote areas, which therefore have no need for commercial or proprietary mobile networks.

Current work practices In many plants radio phones (walkie-talkies) are still an important means of communication between workers. Factories are often divided into many areas that use different radio frequencies for communication to prevent information overload. In some factories workers carry both a mobile device and a radio phone, as the mobile device has not been able to replace the functionality that radio offers.

IT infrastructure Industrial IT systems usually contain a large amount of legacy software as they have been developed over several decades, and it might be difficult to integrate mobile devices into the existing process systems. For example, the mobile solutions introduced by customers might not be specifically designed for mobile devices but rather copied from a desktop environment.

Industrial processes also require extremely secure IT systems, which external persons are not able to access. Companies are

SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Human machine interface

RESEARCH HAS SHOWN THAT, FOR MOST ORGANISATIONS, RUGGED MOBILE DEVICES ARE NOT WANTED IN LOCATIONS WHERE SPARK-FREE EQUIPMENT IS NOT A REQUIREMENT.

Figure 1: Mobile devices like the Apple iPad are being used efficiently in industrial settings.

concerned about utilising mobile devices as they could introduce more complexity and risks into their IT systems. The IT department might value system security more than providing mobile solutions that could improve efficiency. Understanding this trade-off is crucial when designing mobile solutions for industrial automation.

Environment The multitude of different industrial environments also affects mobile device use. Some have impurities such as dust or dirt which can affect the touch capabilities. Other environments might have large temperature variations affecting the battery function and possibly making the mobile device work slower and with longer response times. Others might have humidity. Light conditions can also differ, thus impacting the colour scheme and lighting in the device to achieve the best contrast.

Safety equipment Industrial environments require personnel to wear protective gear. The type of gear can vary based on the safety level of the process but, in general, safety boots, vests, helmets, gloves, ear protection and safety glasses are commonly used. Often protective gear is mandatory in certain areas; for example, when moving in tunnels inside a mine or walking around a plant.

Yet today’s workers spend less time in dangerous areas, as they more often stay in control rooms or other office locations.

Therefore, safety equipment is becoming less of a challenge in certain areas.

Assessing needs Identifying and understanding the specific needs for mobile devices in industrial environments is essential when designing

mobile solutions to create more efficient operators and field workers.

Research has shown that, for most organisations, rugged mobile devices are not wanted in locations where spark-free equipment is not a requirement (as, for example, in oil or gas platforms). Users prefer to replace broken or lost devices with new ones rather than pay extra for rugged options. Users want well-designed backup solutions that will keep the device content safe in case of an accident. The backup solutions would automatically save the content of the mobile device to a secure server to prevent information from getting lost in case of an accident.

And, of course, security must be very high since any break-in to the system could be disastrous. Yet the level of security should not affect the availability of the system: there is no use for mobile solutions if the information cannot be accessed when required.

Another important criterion is that the mobile device should fit into a pocket; otherwise, the device might stay on the work desk and not be carried along during assignments at the plant.

The ability to type with a full keyboard is not considered an issue since the mobile device is not meant to replace a desktop computer - it is just a tool when a field worker is on the move. In many cases, remote workstations for the automation system can be installed at strategic places around the plant for workers to access the process automation system remotely.

These stations have a keyboard and a big screen and can be used when the capabilities of a mobile device are not enough.

Learning to cope with certain limitations of smartphones - for example, the need

6 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

to charge the phone daily - is also not considered an issue since the phone could be charged between one’s shifts together with other equipment that also needs to be charged - eg, lamps. Thus, special devices with extended battery durability might not be necessary.

Current mobile devices that have been specifically designed for industrial environments do not include the latest available interaction technologies such as multitasking or multitouch, nor are they equipped with sensors for measuring the orientation (gyro, accelerometer), proximity of other objects and light conditions. However, the latest smartphones in consumer markets offer these capabilities and a superior user experience. Workers in industrial settings have the same expectations of mobile devices when used as a work tool.

The main advantage of a mobile device in an industrial setting is the real-time access to all information, independent of the worker‘s location. The information includes the process data as well as manuals, blueprints and descriptions.

Up-to-date information is vital for accessing process information. Today, this is accomplished by communicating via radio or phone with the operator in the control room.

For a mobile solution to work, it is important that everyone is included in mobile communication. All personnel should have a mobile device in order to be reachable.

Otherwise, other communication methods are needed, which in turn add complexity to the communication. In an ideal case, people could contact anyone at the plant according to, for example, their availability, responsibility area or expertise without needing to know the actual phone number.

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Human machine interface

Figure 2: Control systems can be supplemented by mobile device usage.

The communication method (for example, phone or video call, text messages or chatting) could also be chosen according to the work task and availability of participants.

This could minimise the operators being overloaded as they could answer some of the questions asynchronously. Mobile devices would also enable private communication, which is not possible with radio phones.

At times personnel in industrial settings use their work or even private mobile devices to take pictures or videos of issues encountered for documentation or to consult with their colleagues. However, they do not have any support for this task from the system or tools provided by their employer. Therefore, industrial mobile devices need to make it possible to collect and share information about the status of the industrial process more directly.

Application development The rapid development of web and mobile applications is very different from the traditional release cycle normally used for industrial systems. Mobile applications have adopted a release cycle of weeks and months, adding new functionality and features as they are updated. The mobile app Angry Birds, for example, has constantly been adding more levels and new characters into the gameplay since it was released in late 2009. Similarly the Facebook application for iOS has also constantly been adding functionality over time instead of releasing a version that does every requested feature from day one.

Such a method for software development (ie, adding functionality in small but frequent instalments) is necessary in the mobile domain as the hardware and

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Figure 3: Example of a control system on a mobile device.

software is shifting so rapidly. That is, the top-of-the-line hardware today will be considered old and replaced by something else tomorrow. These quick software release cycles are something that the industrial sector will have to adapt to by releasing updates as frequently as any other apps for the mobile devices instead of releasing ‘super versions‘ that include every requested feature but with the price of a very long development phase.

Furthermore, with a shift toward quick development cycles it is possible to develop and release software for the industry that solves the most critical-use cases, where mobile solutions will make a huge impact. Continuous updates to the industry applications will then improve and add requested features. Also, ‘rapid prototyping‘ and mobile app development on mobile devices is inexpensive today, which makes the smartphone platforms attractive for industrial domains as well.

What lies ahead The continuous progress in mobile technologies related to user experience and interaction techniques raises the need to allow existing HMIs to evolve so that personnel can use these techniques when interacting with plant systems. Future HMIs should utilise the best parts of these new inventions (including depth sensing, gestures, voice control and new display technologies) and enable users to interact with systems more efficiently and safely.

Research shows that with custommade apps for well-understood scenarios and use cases, mobile device usage in industrial automation can be taken to a completely new level. New developments such as augmented reality, pico projectors

and sensors for detecting the environment can make mobile devices even more powerful in several ways. Augmented reality shows a live view of the reality through, for example, a camera view of a mobile device. The view is then augmented by computer-generated content (graphics).

Augmented reality could benefit, for example, maintenance engineers to show more equipment-related information. For instance, the system could visualise important information related to a device (such as the liquid level in a tank).

Pico projectors are small, handheld projectors that can project full-size images onto any surface. When these are attached to mobile devices (some mobile devices already include one, for example, Samsung Beam), any surface can be used as a display. Then, a maintenance engineer could use his pico projector to project, for example, instructions related to maintenance work directly on top of the device that needs repair.

Mobile devices already include sensors such as a gyroscope and accelerometer to detect the orientation of the device. In the future, mobile devices will probably include more sensors such as infrared cameras or smell detectors to record data about the environment. This information could be used to check if there are abnormal gases in the air or if some equipment has overheated. The gyro and accelerometer could be used to detect where the maintenance engineer is pointing, and identify the device in question to give him more information related to the device.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/U790

SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

PNEUMATIC CONTROL VALVES INSPECTION SOFTWARE

The ASCO Numatics 503 Series of pneumatic directional control valves with ultra-

FARO CAM2 SmartInspect software is

high flow ratings is designed for automation

highly suited to take measurements

and piloting applications across a wide range

without CAD data. In developing the

of automotive and tyre, food and beverage,

software, the focus was on simple,

pharmaceutical, packaging equipment, and

intuitive operation and a short learning

general machinery applications.

phase. This means that even users with minimal background knowledge of 3D

The valve line is available in either spool-and-sleeve or rubber seal models, and proprietary or ISO versions to meet a wide variety of applications.

measurement technology can achieve

The series valves are designed to complement the ASCO Numatics’ G3

very good measuring results within a

fieldbus electronics. When assembled together, original equipment manufac-

short period of time.

turers can leverage assemblies that combine ultra-high flow rates with ease

The software is available in two versions: a Basic version, and a Pro version with an extended range of functions.

The Basic version of CAM2 SmartInspect has a clear and self-explanatory

of use, plus fieldbus technology that provides configurability, flexibility and cost-effective I/O and distribution architecture.

The 503 Series is available in dual 3- and 4-way solenoid air pilot actuated valves. The series valves are available with manifold or individual base mountings, proprietary or ISO 15407.

user interface, as well as very usable

Available ports are 1/4″, 3/8″, 8 mm, 10 mm, push-in, NPTF and G tap.

functions. For example, helpful im-

Operating pressure range is from vacuum to 8 bar, and pilot pressure range

ages can be added to the features to

is from 2 to 8 bar. Ambient operating temperature range is -10 to 50°C.

be measured, so that even untrained personnel can handle the programs very easily.

Ascomation Pty Ltd Contact info and more items like this at wf.net.au/U624

In the Pro version of CAM2 SmartInspect, the 3D live view functions as a visual interface to present the recorded dimensions to optimum effect. Another feature includes measuring length and angle in combination.

REMOTE I/O MODULE

The automatic feature-recognition function makes the measuring process

The LB remote I/O system is designed for minimal

faster, as it assists the user significantly

wiring. Zone 2/Division 2 field mounting, in addition to

in processing a measuring sequence

a single bus line between the remote I/O system and

with few clicks, and automatically sug-

the control room, is said to drastically reduce wiring

gests to the user a range of functions

requirements. Another advantage is that, because

and commands which might be needed

of its compact size, it can be used in systems with

during the measuring process.

little free space .

The combination of CAM2 SmartIn-

The universal LB7x04A module can be used as

spect and the FaroArm or the FARO

an analog input for supplying 2-wire transmitters,

Gage can be used in all sectors that

an analog output for operating proportional valves, I/P

require excellent manufacturing and

converters or on-site displays, a digital input for reading contacts,

product quality. Its flexibility and user-

or a digital output for operating valves and sensors or LEDs. Each of

friendliness enables the CAM2 SmartIn-

the four channels can be parameterised independently of one another

spect to support a range of applications;

when using the module in this way. The status of each channel can be

from incoming goods inspection, initial

read from an LED. The module status is indicated by additional LEDs.

sample inspection, to various inspection

When the universal module is exchanged, the replacement module al-

needs in manufacturing.

ways takes on the parameter settings of the original module, preventing

FARO

errors when replacing modules.

www.faroasia.com/products/cam2smartinspect/sea/

Pepperl+Fuchs (Aust) Pty Ltd Contact info and more items like this at wf.net.au/U835

8 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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Make the unpredictable totally predictable.

© 2012 Swagelok Company

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

Visit swagelok.com/pressure.

NEW PRODUCTS

STAINLESS STEEL KEYBOARD WITH TOUCHPAD The PM-102-SS NEMA 4X is an IP66 specification panel-mount stainless steel industrial keyboard from iKey, and features 101 stainless steel keys that include 12 function keys and a numeric keypad, a stainless steel bezel and integrated touchpad.

The durable device is completely sealed and designed to meet NEMA 4X and IP66 specifications and can operate in temperatures ranging from -20 to +60°C. The bezel measures 449.6 x 229.1 x 40.0 mm. Rear stud mounting bolts are provided for panel mount-

OBSTACLE-AWARE LEVEL INSTRUMENTS The Micropilot FMR5x family of non-contact level measurement instruments now offer multi-echo tracking, which allows the instruments to remain accurate when a tank with obstacles is being filled and emptied.

The traditional disadvantage relating to radar measurement has always been the need to ‘map out’ obstacles in a tank such as heating coils or agitators that provide their own echo response and may be mistaken

ing. Stainless steel is known for its longevity, corrosion resistance and ability to retain strength in extreme temperatures. It is also low maintenance and easy to clean. These characteristics make stainless steel an good material for keyboards used in industrial and food-processing applications.

The industrial keyboard is available with PS/2 or USB interface cables and is compatible with all Windows operating systems.

for the actual process level. This is achieved by evaluating the echo

Interworld Electronics and Computer Industries

response of an empty tank, identifying the response that relates to the

Contact info and more items like this at wf.net.au/U869

bottom of the tank and then recording a static suppression ‘map’ over the echo responses caused by these obstacles. Then, only the signals that range above the map will be evaluated, the obstacles will be ignored.

When a tank is being filled or emptied, however, and the level reaches the obstacle, it too can range below the suppression map, meaning that the level signal is also ignored, causing jumping and erroneous level measurements.

Multi-echo tracking helps alleviate this problem by independently marking all measured signals - not only the level signal. It is a self-learning feature that follows the marked signals at all times and is constantly building a history of their behaviour.

Multiple echoes are identified in the evaluation both above the level

MINIATURE PRESSURE SENSOR

surface and below the level surface in oil-based media. This parallel

The Futek PFT510 miniature pressure sensor is a

evaluation adds security on the measurement determination as direct

general pressure solution for a variety of applications.

and indirect techniques are employed to derive the level.

Purposefully designed with a flat, flush-mount dia-

Endress+Hauser Australia Pty Ltd

phragm, the model avoids clogging at the installation

Contact info and more items like this at wf.net.au/U915

port. With a measuring range of 15 to 700 bar, this 20 mm sensor solution uses strain gauge technology, is suitable for OEM integration, and is compatible with the comopany’s entire line of instrumentation.

OPC SERVER FOR WITS

The combination of the PT510 with Futek’s USB

MatrikonOPC has released its OPC Server for Well Site Information Transfer

solutions offers users the ability to create a system to

Specification (WITS) which provides open data connectivity to well-site data

monitor up to 16 channels side-to-side. In addition,

systems using WITS-compliant devices. Areas in which WITS-based data is

using the linearisation feature within Sensit Test and

common at a well site include geology, drilling, cementing, drill stem testing,

Measurement software, users can expect an improved

electronic data recorders (EDRs) that capture logging while drilling (LWD) and

overall performance and accuracy of the system by

measurement while drilling (MWD) data.

point-to-point linearisation. The platform may also be

With OPC Server for WITS, end users gain direct access to WITS data via any OPC-enabled application, making it easier to share and work with key data on site and with the rest of the enterprise.

Key features of the OPC server include: support for communications through TCP/IP, UDP and/or serial channels; simultaneous support for WITS Level

used by quality inspectors or auditing teams to log data and perform further analysis.

Metromatics Pty Ltd Contact info and more items like this at wf.net.au/U783

0-compliant active and passive devices; read and write access to available data points; and full compliance with OPC DA 1.0, 2.0a and 3.0 specifications.

MatrikonOPC Contact info and more items like this at wf.net.au/U793

10 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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leading the way

Experion Virtualization Solutions, leading the industry in innovation.

Honeywell was the first automation supplier to provide a comprehensive virtualization solution consisting of hardware, software, guidance and support from design through implementation and management.

Now, Honeywell introduces a Premium Platform to host Experion Virtualization Solutions, leveraging blade server technology to deliver advanced virtualization capabilities and superior lifecycle benefits. Honeywell is the proven leader to navigate the world of open systems and changing technology.

Changing control by controlling change.

To learn more about Experion Virtualization Solutions, visit www.honeywellprocess.com. Š2013 Honeywell International, Inc. All right reserved.

NEW PRODUCTS

CENTRAL CONFIGURATION FOR INDUSTRIAL WLANS Phoenix Contact has equipped the WLAN 5100 series industrial WLAN access points with a cluster management function. This makes it easier to configure and manage access points (APs) in small and medium-sized WLAN networks.

A web browser is used to configure the network via the web interface of any AP. Next, the AP independently transfers the settings such as the network name (SSID), WLAN encryption and quality of service to the other APs in the WLAN network, or cluster, which can contain up to 20 access points.

This access point supports the new high-speed IEEE 802.11n WLAN standard on the 2.4 and 5 GHz bands at up to 300 Mbps. Additionally, the MIMO (multiple input multiple output) technology with three antennas improves the reliability, range and speed of wireless communications, especially in industrial environments.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/U728

REMOTE I/O MODULE The Artila Electronics RIO-2010 webbased remote I/O control module is

RUGGED DAQ SYSTEM

designed for simple, stable performance,

The NI cDAQ-9188XT is a rugged,

making remote control of I/O straight-

8-slot NI CompactDAQ ethernet

forward and dependable.

chassis that is designed for dis-

It is ethernet ready and equipped

tributed or remote measurements in

with eight relays, 16 opto-isolated

extreme environments. The device

digital inputs and a 1-wire interface for

can withstand temperatures from

digital temperature sensor connection.

-40 to 70째C, 50 g shock and 5 g vi-

The built-in web server allows users to

bration. Engineers in the automotive,

access the I/O and remotely control

military and aerospace industries

the RIO-2010 relay using standard web

have used it to successfully acquire

browsers.

data and avoid costly repeat tests.

Using the standard Modbus TCP

In addition, the chassis is the

protocol, the module can be easily

first in the NI CompactDAQ platform to offer an onboard watchdog with defined

integrated into SCADA and industrial

safe states to help protect tests and equipment. The platform includes 10 chas-

automation systems. The module also

sis options, three buses and over 50 C Series modules with a wide range of

comes with an RS485 serial interface for

connectivity and I/O. The platform also has native integration with NI LabVIEW

applications that require Modbus RTU/

system design software, which provides signal-processing libraries and user-

ASCII. The built-in web server allows

interface controls designed for data visualisation.

users to customise their own webpage

The NI CompactDAQ platform also now supports the LabVIEW Electrical Power

using standard web-editing tools and

Suite. With this toolkit, NI CompactDAQ users can integrate power-analysis func-

AJAX dynamic page technology.

tions such as energy, frequency, voltage unbalance and event detection into their

Micromax Pty Ltd

monitoring systems.

Contact info and more items like this at wf.net.au/U805

National Instruments Australia Contact info and more items like this at wf.net.au/U862

12 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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NEW PRODUCTS

SYSTEM-WIDE AUTOMATION DEVELOPMENT SOFTWARE ABB has launched an engineering development tool suite for industrial automation projects. Automation Builder provides an integrated development environment for control and motion

MICROWAVE LEVELLIMIT SENSOR

systems based on PLCs, safety PLCs, robotics, motion control and related automation components.

Whether in bulk solids or liquids,

Combining all of the tools required for configuring, program-

the VEGAMIP 61 microwave

ming, debugging and maintaining automation projects from

barrier is designed to detect the

a common intuitive interface, Automation Builder addresses

limit level with absolute certainty

the largest single cost element of most of today’s industrial

in very rough process condi-

automation projects: software.

tions. The sensor is insensitive to dirt, dust and build-up.

Automation Builder builds on the company’s Control Builder

It is especially adapted to the requirements and needs of

Plus tool for programming PLCs. This provides PLC development

the bulk solids industry.

resources in the form of the standards-compliant CoDeSys IEC

The measurement is non-contact and the sensor itself has

61131-3 development environment and the Panel Builder tool

no direct contact with the medium. This is advantageous

for creating HMIs. These are now complemented by tools for

particularly for abrasive media or very high temperatures.

configuring and programming the latest generation of safety

In such cases, the sensor can simply measure from the

PLCs, and the RobotStudio tool for simulating and program-

outside, through a microwave-permeable window, such as

ming industrial robot applications, as well as Mint WorkBench

ceramic or plastic.

and pre-built and tested libraries for controlling drives, and

Also, when used for level detection of liquids or object detection, the microwave barrier offers many advantages over other measuring principles.

other devices connected via fieldbuses, networks or the web.

The suite integrates all these capabilities into a single environment served by common data and intuitive user interface.

The device can be used both as maximum and minimum

This provides data consistency that eliminates the need to enter

level sensor, and fits in VEGA’s plics concept, offering all

data multiple times. It also avoids the programming effort and

the advantages of a modular system. Housings of plastic,

issues associated with exchanging data between the control-

aluminium or stainless steel as well as different antenna

ler and all of the various devices in the automation system.

systems and process fittings are at the user’s disposal,

These devices include servomotor drives, robot arms, operator

making it possible to configure the sensor to meet exact

panels and I/O. Third-party devices can also be interfaced into

requirements.

the environment.

VEGA Australia Pty Ltd

ABB Australia Pty Ltd

Contact info and more items like this at wf.net.au/U865

Contact info and more items like this at wf.net.au/U357

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SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

> SAFETY PLC WITH ETHERNET/IP

>

The addition of the EtherNet/IP communication functionality is a firmware upgrade option to existing PSS4000 PLC devices.

SOFTWARE-DESIGNED CONTROLLER

Pilz Australia Industrial Automation LP

WF.NET.AU/U682

The cRIO-9068 software-designed controller has been completely redesigned but maintains full NI LabVIEW and I/O compatibility with the CompactRIO platform.

National Instruments Australia

WF.NET.AU/U832

>

>

TOUCH-SCREEN DATA LOGGER The ALMEMO 710 touch-screen data logger

OXYGEN ANALYSER

from Ahlborn can connect to and evaluate all new (D7) as well as existing sensors.

The compact and cost-effective XZR200

Bestech Australia Pty Ltd

oxygen analyser is capable of measuring

WF.NET.AU/U951

percentage oxygen to better than 1% of span.

AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/U900

UNIVERSAL SURGE ARRESTORS The BXT ML2 surge arrestor modules provide optimal protection for measuring and control circuits, bus systems, alarm systems and telecommunications.

>

DEHN + SOHNE GmbH + Co KG

WF.NET.AU/U864

14 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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NEW PRODUCTS

PRESSURE SENSOR The Model S-20 pressure sensor has been designed for a wide range of applications and demanding measuring requirements. It offers continuous measuring ranges between 0-0.4 and 0-1600 bar, which can be combined with all common output signals, process connections and electrical connections.

As an option, the model S-20 is available with different accuracy classes (0.125, 0.25 and 0.5% BFSL), extended temperature ranges and customer-specific pin assignments. Even under the most adverse conditions, the pressure transmitter is claimed to deliver accurate results.

WIKA Australia Contact info and more items like this at wf.net.au/U623

SWITCH MODE POWER SUPPLY The FEAS SNT15024-K switch mode power supply is designed to withstand inadvertent polarity reversal while also providing an output that is protected from short circuit conditions.

Constructed within an industrial IP69-rated aluminium casing and with its electronic system completely sealed by a durable resin, the power supply is designed for applications that must operate under the harshest of environmental conditions. Despite its compact dimensions, this FEAS power supply is said to

DUAL AVERAGING MASS FLOW METER

conform to the highest level of EMC standards, providing

The ST102A air/gas thermal mass flow meter from Fluid Compo-

fault-free operation within applications prone to the effects of

nents International (FCI) features a dual-element averaging system,

radio signal disturbances.

improving installation repeatability and accuracy for larger-diameter

Device protection includes an adjustable fuse mode feature

pipes and ducts.

to provide a safe shutdown in overload conditions. Shutdown

Flow measurement applications involving line sizes 300 mm or

on overtemperature is followed by an automatic restart, while

greater can realise improved installation accuracy and repeatability

a standby function allows the unit to turn off when not in use.

by averaging the flow rates of two elements. Distorted, swirling and

Output voltage is 24 VDC at up to 25 A, with an operating

non-repeatable flow profiles can result in decreased accuracy of

temperature range of -40 to +70°C. Automated Control Pty Ltd Contact info and more items like this at wf.net.au/U837

single point meters. It is often impractical or impossible to provide the required straight run for a fully developed flow profile in large lines.

The Model ST102A flow meter has transmitter electronics that average the input from two independent flow elements into a single output. Each flow element can be independently configured for insertion length and process connection to allow installation flexibility.

One flow element can be integral with the flow transmitter, or both can be configured as remote for easier access and visibility to the digital display/optical four-button user interface. The flow transmitter also provides independent information for each flow element, saving time when performing service checks.

The flow meter can be calibrated to measure virtually any process gas, including moist gas, mixed composition gases and dirty gases. The basic insertion style air/gas meter features a thermal flow sensing element that measures flow from 0.07 to 305 NMPS with accuracy of ±0.75% of reading, ±0.5% of full scale. Designed for rugged industrial processes and plants, the flow meter is suitable for service up to 454°C. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/U901

16 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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CASE STUDY

Intelligent valve actuators for Caltex terminal upgrade Rotork intelligent electric valve actuators and two-wire digital control systems have been specified for a major plant upgrade at the Caltex Kurnell site in Sydney, Australia. The upgrade project is converting the existing refinery site into an import terminal for the storage and distribution of petrol, diesel, jet fuel and fuel oil.

A large proportion of the 300 actuators involved are Rotork’s latest IQ3 units, the third generation of its non-intrusive intelligent electric actuator product range. All the actuators will be monitored and controlled by 10 hot-standby Rotork Pakscan P3 bus networks. Designed specifically for the remote operation of valve actuators and the spacious environments associated with tank farms, Pakscan provides the link between actuators in the field and the host control system.

Many of the actuators will be supplied on new valves while a number are being retrofitted by Rotork Site S e r v i c e s A u s t ra l i a o n t o existing hand-operated valve instal lations. Retrofitting areas include the terminal berths, where IQ3 actuators are being used to motorise the double block and bleed manifold valves. Rotork’s re t ro f i t re s p o n s i b i l i t i e s encompass surveying and measuring the on-site valves, sizing and installing the new actuators and assisting with the integration and commissioning of the Pakscan networks throughout the site.

Launched in 2012, the IQ3 has introduced new levels of functionality and asset management abilities for valve actuation.

Advanced IQ data logging and communication capabilities have been increased in response to the end users’ desire to access more data, both in the field and in the control room.

The large, toughened glass, wide-angle indication window is the focus of attention for non-intrusive, two-way wireless communication and multifunctional indication. The window provides positional and warning icon information, while actuator set-up and operating menus along with detailed diagnostic and operational data screens are clearly displayed in dot matrix

18 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

format. Diagnostic screens show the valve torque and usage profiles along with service logs, facilitating real-time analysis directly at the actuator.

A handheld setting tool with Bluetooth wireless technology also enables the data from the actuators to be transferred to a PC for analysis using Rotork Insight2 diagnostic software. Valve maintenance requirements can be identified and anticipated, eliminating unplanned interruptions or over-cautious planned maintenance outages.

The IP68 watertight and temporarily submersible doublesealed enclosure is universal to all actuators, including those with explosion-proof certification, ensuring long-term reliable performance in the most challenging environments.

The Pakscan P3 digital control system is capable of monitoring and controlling up to 240 actuators without repeaters on a single highway with a length of up to 20 km. Pakscan combines high reliability and efficiency with low maintenance costs, incorporating secure field communications with in-built network redundancy to maintain control even in the event of equipment or cable failure.

At the P3 master station, c u rre n t s t a t u s a n d a l a r m indication is updated when data has changed, providing real-time status indication of every actuator on the network. Information includes torque profiling to provide an accurate indication of valve performance.

Reprogramming of individual actuator parameters can be performed at the master station or remotely via the host serial network or via ethernet.

An event logger captures and saves every major change in the status of the actuators as well as recording all digital and analog commands. Logged data is viewable at the master station or on web pages, where the data can also be stored for future asset management reference.

Rotork Australia Contact info and more items like this at wf.net.au/U803

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www.sipos.com

Cerebral Strategy

Avoid a brainless blueprint Planning to modernise without SIPOS makes no sense.

Optimise your upgrade with our advanced electric actuators. This is intelligent forethought that will increase the flexibility, efficiency and cost-effectiveness of your plant.

Talk to us – we have the actuators with smart heads.

78 Dickson Avenue, Artarmon NSW 2064 Telephone: +61 2 8437 4300, Facsimile: +61 2 8437 4333 info@barron.com.au

NEW PRODUCTS

COOLING WATER PUMPS Specially designed for pumping large quantities of critical cooling water within fossil and nuclear power-generation applications, the CUP-CVP, concrete volute pump, from ClydeUnion Pumps offers high performance and efficiency, while providing high plant availability.

Power used in the generation of electricity reduces the overall power plant efficiency. Reducing the power consumed for major applications such as cooling water pumps therefore offers significant sustained increases in plant efficiency and profitability. Availability of the cooling water pump is also critical to plant running times and production capacity.

The pump is designed to provide higher flow rates than conventional vertical bowl pump designs, thus reducing the number of pumps required. Its design operates at higher efficiencies and experiences minimal wear during operation due to its low running speed, said to result in exceptionally high reliability and availability approaching 100%. The pump has been shown to exhibit no noticeable deterioration in efficiency over 100,000 hours of operation in power-generation applications, with a minimum service life of 10 to 12 years between internal maintenance inspections.

The pump can be provided for flow rates up to 120,000 m3/hr and delivery heads up to 50 m. Once installed, the design incorporates a packed gland with a pneumatically operated inflatable seal (to prevent flooding when the packing is replaced) and a removable inner cartridge for ease of maintenance. Journal bearings are oil-bath lubricated and tilting pad thrust bearings are used to improve reliability and increase bearing life. An efficient, balanced impeller reduces thrust loads and increases stability.

SPX Flow Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/U266

PUSH-IN TERMINALS FOR UP TO 95 mm² The PT Power 95 high current terminals from Phoenix Contact make it possible to easily connect and wire rigid or flexible ferruled conductors up to 95 mm² directly and without the need for tools.

As soon as the conductor is inserted, the contact springs open automatically. With lower insertion forces, it is now easier to plug in a conductor and establish a contact. The high contact forces exceed those stipulated by the relevant standards and ensure that high-quality, reliable conductor contacts are established. All it takes to remove a conductor is to press the release button that can be actuated with a standard screwdriver. This transfers the force to the inner contact springs and opens them to their maximum extent. The orange colour of the button clearly identifies it as an actuating element, thus preventing mistakes from being made.

The PT Power 95 range of high current terminals rated at 232 A and 1500 V includes several terminal types. These include universal terminals with and without test sockets, a protective earth terminal that automatically contacts the mounting rail when mounting, preassembled terminal blocks, and flange terminal blocks for direct mounting without mounting rails.

The fully insulated AGK pick-off terminals with optional snap-on technology facilitate voltage tapping for two 16 mm² conductors. Multi-pin insertion bridges are available for simple potential distribution. Large labelling materials and testing accessories from the Clipline complete terminal block system line round out the product range.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/U530

INDUSTRIAL COMPUTER Micromax has announced the Artila Electronics Matrix-516, the new generation of its ARM-based box computers.

Artila’s Matrix-516 industrial box computer is a small form factor, Linux-ready computing platform that offers reliable, 24/7 unattended control at low-power consumption levels.

The box computer is suitable for a variety of industrial applications, including intelligent transportation systems, building automation, energy-saving systems and factory automation. It ensures high performance with a 400 MHz Atmel AT91SAM9G20 CPU, 64 MB SDRAM and 128 MB NAND Flash. It is adaptable, offering multiple I/O interfaces, including two LAN ports, eight isolated RS485 serial ports, two USB hosts, a microSD and 21 GPIOs. The box computer offers easy development of C or C++ programs or web-based applications such as SQLite+ and PHP. The box computer includes a fail-safe design and a Linux environment that is highly scalable and configurable. It includes a Data Flash with a backup Linux file system, which provides system recovery and start-up if necessary. For portable control, the box computer has a pre-installed Linux OS, allowing users convenient operation via telnet or transfer files using FTP. Advanced customisation is also available upon request.

Micromax Pty Ltd Contact info and more items like this at wf.net.au/U836

20 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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Served up on a plate

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

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

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

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

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

We make ideas flow

CASE STUDY

CSIRO helps smelters cut energy consumption Large smelters in electricity-intensive metal-winning industries can use as much power as a medium-sized city, so finding ways to reduce their energy requirement is a high priority.

The Australian research agency CSIRO, in partnership with industry players, is assessing and testing new electrical connection systems in a bid to help smelters cut their electricity consumption and associated emissions.

To assist industry partners in the design and testing process of new electrical connection systems, CSIRO needed to develop a simulation capability that could examine the sophisticated physics involved in the electrical supply infrastructures of large-scale facilities and assess the impact of possible changes.

However, because it is both costly and difficult to test new configurations in a functioning facility, engineers used simulation tools to determine whether new designs will work and how to calculate the power savings they will deliver to the operation.

“Modelling and simulation are key tools for future process and design improvement to help our industry improve electrical energy efficiency,” said CSIRO Research Consultant David Molenaar. “An opportunity existed to harness the infrastructure of CSIRO to develop a new, more-advanced modelling solution.”

Essential features of the solution included the ability to assess the performance of electrical connections with respect to energy efficiency in large electrical systems based on the governing physics that is of a fully coupled thermal-electrical-mechanical nature.

The CSIRO team spent 12 months conducting a comprehensive benchmark study that examined all suitable tools available on the market. Performed in partnership with Swinburne University (Melbourne), the benchmarking process incorporated a simple contact problem and a more complex real-world problem.

After assessing three potential providers, CSIRO decided to adopt the Dassault Systèmes 3DExperience Platform with the Simulia Abaqus finite element analysis (FEA) application for realistic simulation, through its partner Simuserv, a provider of simulation consulting services.

“The decision to adopt Simulia was based on its ability to solve the fully coupled thermal-electrical-mechanical equations and to achieve convergence in highly nonlinear problems, including complex contact scenarios,” said CSIRO team member Dr Dayalan Gunasegaram. “We also liked its ability to scale and run on our high-performance computing platform.”

Other advantages included the ability of the application to support subroutines that can be used by CSIRO clients in their own installations of the Simulia code. This would allow the team

22 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

to develop sophisticated modules that clients could then bolt-on to their existing, in-house systems for future testing.

Once the decision to proceed was made, the CSIRO team focused on installing the code on the organisation’s highperformance computing (HPC) architecture. This facility includes a 146 compute node CPU cluster that resides within CSIRO’s HPC facility. The facility also incorporates a GPU cluster with 172,032-streaming processor cores on 384 GPUs, which was ranked 183rd in the world (in November 2012). This vast computing capability, together with the efficient parallel performance of Simulia, allows CSIRO to deliver solutions to clients in short timeframes even when computationally intensive work is required.

With its 3DExperience technology now in place, the CSIRO team has the ability to undertake detailed studies of industrial electrical systems and infrastructures. “We are now receiving calls from clients around the world who are keen to work with us to find more energy-efficient solutions for t h e i r o p e ra t i o n s , ” M o l e n a a r said. “With Abaqus on our HPC architecture, we can deliver very accurate results to our clients in commercially relevant timeframes that we simply could not have achieved before.”

The new capabilities meet the overall objectives of CSIRO. While it increases the efficiency of the Australian industry, the application also allows the research organisation to play a valuable part in minimising the environmental impact of energy-intensive industrial activity on a global scale.

With the Simulia-based infrastructure, CSIRO’s clients are able to gain a much clearer view of their energy infrastructure’s performance and make more informed decisions about potential changes. The CSIRO team works to calculate possible performance improvements and cost reductions for each project.

The end result is improved energy efficiency and a reduced environmental footprint.

Based on its success with the Simulia application to date, the CSIRO team is planning to extend its usage during the next few years. The networked nature of the software will allow it to be used more broadly within the organisation to run a variety of computationally intensive simulations. As client demand for the services continues to grow, CSIRO anticipates the size of the team will also increase.

“By harnessing tools such as Simulia Abaqus, we are able to compete on a world stage. The support of Dassault Systèmes has been integral to the success of the implementation project and the value that is now being delivered to our clients,” he concluded.

CSIRO Head Office Contact info and more items like this at wf.net.au/U615

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Domino A-320i Ink Jet Coder No maintenance, no fuss.

The intelligent i-Tech ink system monitors how you are using ink and works out when consumables are due for replacement.

The revolutionary Qube fluid delivery system contains working ink & ink filters and is a system that anyone can change in less than 10 minutes eliminating the need for a service call out.

With the ability to code up to 4 lines of text at a speed of up to 325m per minute, the A-320i is the most reliable class-leading filtration and modulation ink jet coder system.

Contact us to find out more about the Domino iTech range.

Phone: 1300 467 446

Email: sales@insignia.com.au

Web: www.insignia.com.au

NEW PRODUCTS

MULTI-FIBRE ETHERNET SWITCHES The Moxa EDS-210A series are 10-port industrial unmanaged switches that can deliver gigabit speed and multiple fibre connections for high-bandwidth data convergence and long-haul data transport for small-scale and widely distributed edge applications, such as factory floor automation and IP surveillance uplinks for ITS networking.

The series offers two types of port combinations for flexible network connectivity. The EDS-210A-1GTX-1GSFP-4SFP supports up to 2 gigabit uplinks (combination of a gigabit fibre and a gigabit copper port), four 100BaseSFP, and four 100BaseTX ports. The EDS-210A-1GSFP-1SFP consists of a gigabit copper, a 100BaseF and eight 100BaseTX copper ports.

The EDS-210A series is suitable for high-speed industrial applications that require flexible fibre/copper port combinations, such as ITS surveillance systems that require gigabit ports for uplink to control rooms, and fast ethernet ports for edge-level connectivity, such as IP cameras and field devices. The flexible connectivity options are also suitable for factory automation networks that require data transmission using a mix of fibre and copper media.

For industrial-grade reliability, the EDS-210A series switches provide 12/24/48 VDC redundant dualpower input, high-level EMI/EMC shielding, and two operating temperature range options: -10 to 60째C and -40 to 75째C. Power and port-status LED displays on the front panel allow quick troubleshooting to reduce system downtime. The EDS-210A series switches can be easily installed on any DIN rail or distribution box in harsh industrial environments.

Madison Technologies Contact info and more items like this at wf.net.au/U526

24 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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NEW PRODUCTS

VIDEOSCOPE The Olympus IPLEX LT portable industrial videoscope is a compact and lightweight instrument (weighing 2.7 kg), with good portability and functionality. The large 6.5″ VGA monitor produces high image clarity, which allows for more accurate detection of very small defects. The device is capable of still image and movie recording with storage to a USB flash drive, and can be easily operated by users with any level of experience.

The IPLEX LT is a rugged and durable instrument that provides advanced inspections allowing smooth, uninterrupted operation in almost any environment including rain, sand, dust, high temperatures and explosive atmospheres. The stand-alone monitor can be convenient for group viewing sessions and training.

Applications include inspection of heat exchangers, turbines, gearboxes, automotive parts and aircraft. It also features a removable Li-ion battery and is IP55 compliant.

TechRentals Contact info and more items like this at wf.net.au/U436

PANEL PC The iEi IOVU-430S is a costeffective industrial panel PC integrating a 4.3″ screen with projected capacitor multitouch functionality. The screen offers a comfortable brightness (400 cd/m2) and a wide screen resolution of 480 x 272 pixels.

The panel PC is powered by an XScaleR PXA270 416 MHz RISC processor. It includes 128 MB DDR2 RAM, one 1 GB SD card with a pre-installed Windows CE 5.0 image, and a large number of connectivity options including a LAN port, an RS232/422/485 serial port, a USB 1.1

Wind Energy

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port, a CANbus 2.0B port and six digital I/O channels.

The panel PC has an IP65 front design, fanless cooling system, panel or wall mounting, VESA 50 support, an extended operating temperature range (0 to 50°C) and 12-36 VDC voltage input. The device has been designed for 24/7 operation. For software developers, all SDK are provided for Windows CE 5.0.

The panel PC has been designed as a HMI solution for factory automation or machine automation, point of information or transport applications.

ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/U866

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

SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

NEW PRODUCTS

UPDATED DEVELOPMENT SYSTEM National Instruments has released NI LabVIEW 2013, the latest version of its system design software for engineers and scientists. With LabVIEW 2013, NI integrated the latest and most innovative technologies into the software while reducing design complexity from basic measurements to full test platforms.

Upgraded LabVIEW 2013 benefits include native support for the newest hardware from vendors like ARM and Xilinx, including the Xilinx Zynq All Programmable system on a chip used in high-performance systems; enhanced application reliability and quality for complex applications through a suite of code management, documentation and review tools, including a new Subversion plug-in from Viewpoint Systems; streamlined deployment technologies for developers who want to deliver professional applications to users, including a new tool from Wirebird Labs; and the ability to deliver systems on the latest mobile platforms for iOS and Android that enable dashboards for remote monitoring and system control.

These updated capabilities are delivered through the familiar LabVIEW programming paradigm, eliminating developer need for expensive new toolchains or the acquisition of OS- or hardware-specific training or talent.

LabVIEW 2013 emphasises the incorporation of ongoing user feedback through the inclusion of more than 100 additional features and improvements in the LabVIEW editor. Additionally, NI introduced an in-product storefront for the LabVIEW Tools Network, a community of LabVIEW software addons that recently surpassed two million product downloads. Customers with an active service contract will benefit from an expanded library of online training resources from the use of realtime targets to programming for FPGAs and even object-oriented programming.

DUAL-INPUT FLOW RATE/TOTALISERS The Precision Digital ProVu PD6262 and PD6363 dual-input flow rate/totalisers feature independent programming of inputs, including separate selection of input type and scaling.

The PD6262 panel meter supports dual analog inputs of 0-20 mA, 4-20 mA, 0-5 V, 1-5 V or Âą10 V. The PD6363 panel meter supports dual pulse inputs, including square wave, open collector, NPN, PNP, TTL or switch contact signals. Both meters provide integrated math functions for rate or total flow calculations: addition, difference, summation, multiplication, division, min/max, weighted average, ratio and concentration.

The PD6262 and PD6363 feature rugged NEMA 4X front panels, and the optional SunBright display can be read even in direct sunlight, smoke, fog, dust or at a distance. The meters are designed for quick and easy display of local or remote information in a variety of flow applications, such as municipal water measurement, wastewater treatment or chemical mixing. For

National Instruments Australia

hazardous areas, such as oil and gas

Contact info and more items like this at wf.net.au/U833

production, the meters are also available as explosion-proof, IP68, NEMA 4X ProtEX-MAX models.

COLOUR SENSOR The latest colour sensor from Wenglor provides colour recognition even with changes in distance and is capable of evaluating up to three colours simultaneously.

A small spot and a large working range are made possible due to single-lens optics. All sensor settings can be selected by means of teach-in, as well as via the RS232 interface. Values generated by the sensor can be read out via the interface or digital switching outputs.

The colour sensor is equipped with two digital inputs; three switching outputs and an RS232 port for reading out RGB, XYZ and HSL colour values.

The intensity of the emitted light can be increased in order to detect dark objects. With a spot diameter of 3 mm and a working range of 30-40 mm, complex detection tasks can be implemented in a simple, uncomplicated fashion.

The graphic display allows for easy, intuitive use with multilingual menu prompting. Additional password protection offers security against unauthorised access.

Supply voltage is 10-30 V, and current consumption at 24 V is less than 80 mA. Switching frequency is 1.8 kHz, and response time is 300 Âľs.

Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/U625

26 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

The ProVu flow rate/totalisers feature bright red LED displays. The upper display is 15 mm high and shows a full six digits. With the total overflow feature, up to nine digits of total flow can be displayed. The lower display is 12 mm.

The PD6262 and PD6363 are UL and CUL listed and are CE certified for high noise and RF immunity. The explosion-proof models, ProtEX-MAX PD8-6262 and PD8-6363, provide IP68, NEMA 4X enclosures, SafeTouch through-glass button programming and Modbus RS485 serial communications standard.

Precision Digital Corporation www.predig.com

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NEW PRODUCTS

INFRARED LINE SCANNER AND THERMAL IMAGING SYSTEM The Ircon ScanIR3 Series infrared line scanners and thermal imaging system includes a choice of eight models that provide accurate, real-time thermal imaging in a wide variety of industrial applications, including continuous sheet and web-based processes, as well as discrete manufacturing.

Combined with Ircon ScanView Pro software, the ScanIR3 scanner is designed for reliability and continuous operation in harsh industrial environments. Its robust housing incorporates standard water cooling and air purge, and features built-in laser sighting. A processor box provides universal I/O capabilities in the field without the need for an external computer.

Unlike point sensors that measure a single point, the line scanner measures multiple temperature points across a scan line. Its motorised mirror scans at rates up to 150 lines per second, allowing rapid detection of temperature non-uniformities and hot spots. Rotating optics collect infrared radiation at 1024 points within a 90째 field of view, and industry-leading optical resolution (up to 200:1) enables detection of smaller temperature anomalies.

The ScanView Pro software allows custom configuration of ScanIR3 operating parameters, and display of thermal images and temperature profiles on a standard PC. The software includes features to subdivide thermal images from the ScanIR3 line scanner into portions of specific interest.

The ScanIR3 line scanner is offered with an optional high-temperature enclosure system designed to protect the scanner from exposure to ambient temperatures up to 1090째C. The line scanner can then operate in high-temperature processes, such as in manufacturing steel and other metals, as well as glass and other minerals.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/U799

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SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

IMPROVE PNEUMATICS PERFORMANCE THROUGH FILTRATION SYSTEM DESIGN Scott Minato and Barbara Pontisso, Numatics, Inc

© iStockphoto.com/mangojuicy

28 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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Pneumatics

In an ideal world, industrial air or gas supply lines would be free of particulate, water, oil and other contaminants. In the real world, however, supply lines typically deliver some contaminants along with the air or gas they were designed to carry.

L

eft unchecked, contaminants in an industrial air or gas supply will cause efficiency losses, maintenance headaches and the premature failure of pneumatic components.

Cleaning up an air or gas supply can be as easy as installing a filtration system. These systems employ one or more filters to remove contaminants before they reach the pneumatic equipment. What’s not so easy is selecting the right type of filtration system for a particular application.

In part, the difficulty comes from the different filtration requirements across industries. Food and beverage, semiconductor and automotive plants, for example, all have different filtration needs based on their specific pneumatic systems and operating environments.

And in part, the difficulty in choosing the right filtration approach involves differences in the filters themselves. Not all filtration technologies are created equal in terms of their intrinsic performance characteristics and suitability to a given application.

Choosing the wrong filter or applying it incorrectly can actually do greater harm than good.

To tailor filtration systems to the job at hand, it’s important to understand not only the capabilities of different filter elements but also how to combine them in series.

Filter types Effective air filtration starts with an understanding of the different types of filter media and what they can do. The most common types used in industrial settings include water separators, particulate filters, coalescing filters and adsorbing filters.

Water separators Water or moisture can quickly damage pneumatic components, causing valves and cylinders to stick. Water separators use the centrifugal forces generated by an internal spinning mechanism to remove large quantities of water and water-borne contaminants.

While typically used to remove bulk liquids and large water-borne solids, water separators also protect other filter elements from large liquid loads that could shorten filter life.

Coalescing filters come in different grades. Coarse coalescers are often used for mainline plant filtration, while fine coalescers are used for applications such as paint spraying, robotics and pneumatic tools. The ultrafine coalescer is mainly a point-of-use filter specified for critical processes such as semiconductor packaging and instrumentation.

Adsorbing filters As a final step in certain applications, an adsorbing filter may be added to remove oil and hydrocarbon vapour from the compressed air stream. This type of filter is used immediately downstream from a coalescing element. Because optimum adsorption takes place at lower temperatures, it’s best to install the filter as close to the point of use as possible. Adsorbing filters are often used for breathing air preparation as well as food and drug applications that have direct product contact with exhaust air.

Filter design and construction While these common filter types are sometimes referred to generically, keep in mind that there are substantial quality and performance differences between filters from different sources even if they have the same nominal filtration specification. These differences often boil down to design and manufacturing methods.

Coalescing filters are a prime example of why design and manufacturing matters. Commodity coalescing elements typically employ a mechanically wound filter media, but quality and performance can be dramatically improved by employing a vacuumformed filter media composed of glass fibres and an epoxy binder.

This manufacturing difference is not trivial. The vacuum-formed design traps contaminants through the entire cross-section of the filter. The result is a lower pressure drop and more capacity than a comparable wrapped filter that traps contaminants primarily on the surface and quickly clogs as a result. Filters with the vacuum-formed design have an initial pressure drop of just 1.5 psi in a dry condition at rated flow - far lower than a typical wrapped filter.

Particulate filters Large particles such as rust, debris and desiccant dust can wear out pneumatic components prematurely. These contaminants are often generated by old carbon steel pipes, compressor intakes and desiccant air dryers. The best particulate filters feature pleated designs to maximise the surface area available to trap dirt particles. Particulate filters are often used to achieve up to a 3-micron particle removal in dry systems.

Coalescing filters Coalescing filters are the next line of defence in an air filtration system and can do a good job removing water, oil, rust and other contaminants from the air supply. The design of coalescing filters differs from manufacturer to manufacturer. The Numatics Delta Series coalescing filter elements, for example, consist of a porous network of borosilicate glass fibres. As air moves through the filter element, solid particles are trapped and liquids are formed into droplets that drain away.

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Figure 1: Air flows from the inside to the outside of a filter element through progressively larger openings in the media. As contaminants move through the element, solid particles are trapped and liquids are formed into large droplets.

SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

Pneumatics

Figure 2: Typical contaminant size in microns (µm).

Vacuum forming also allows the customisation of filter element recipes to achieve desired filtration levels. Filter engineers can tweak the vacuum-forming process to an extensive range of gradient densities to form coalescing elements ranging from 0.01 to 1 micron.

Construction differences apply to other filter types too. The Numatics Delta Series adsorbing filters, for example, consist of fine activated charcoal impregnated on polyester. These activated carbon particles have a strong affinity to vapour and are highly efficient due to the extensive surface area present.

Effective filter combinations Most filtration systems require multiple filter elements, working together to remove the full spectrum of particulate sizes and compositions capable of harming downstream components. The specific combination, or series, of filters will vary depending on the application’s air quality requirements.

Food and beverage or semiconductor applications, for example, may require three different filters, including ones capable of removing submicron particles. Others such as main line plant filtration may require just a coarse particulate filter. Here are a few examples of filter combinations used in various applications: • Blow moulding: 3-micron particulate filter; 0.01-micron fine coalescer; vapour adsorber.

• Electronics: 3-micron particulate filter; 1-micron coarse coalescer; 0.01-micron ultrafine coalescer.

• Food packaging: 3-micron particulate filter; 0.01-micron fine coalescer; vapour adsorber.

• Pneumatic control systems: 3-micron particulate filter; 0.01-micron fine coalescer.

• Process air: 1-micron coarse coalescer; 0.01-micron fine coalescer; vapour adsorber.

• Semiconductor packaging: 3-micron particulate filter; 0.01-micron fine coalescer; vapour adsorber.

Bear in mind that combinations of filters do not always require separate products. In some cases, different filter elements can be combined, saving space and simplifying the ordering process.

Numatics Delta Series coalescing filters, for instance, have a pleated 3-micron pre-filter available as an option, which can eliminate the need for a separate coarse particulate filter. This two-in-one approach saves both space and money because the prefilter can share the same housing with the coalescing filter.

30 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

Figure 3: At left, a 228x magnification of a borosilicate glass fibre coalescing filter shows a new 0.01-micron filter element. At right, a 40x magnification shows a filter element that has trapped various metal, oil and hydrocarbon contaminants.

Filtration is part of a system Too many machine builders and installers fail to consider air filtration. Or if they do, it’s just an afterthought. Filtration’s biggest benefits, however, come when the air filter and pneumatic components work together as a system. Only then will the filter offer the maximum protection against contaminants while preserving pneumatic efficiency.

Matching the filtration technologies with specific pneumatic system can be daunting. So it’s helpful to seek out an experienced filtration supplier who can help strike the right balance between air quality and pneumatic system performance.

Industry spotlight: Proper filtration solves mouldy bread dilemma Food and beverage processing requires compressed air filtration to protect not just the pneumatics but also the product. Recently, a large commercial baker discovered that air filtration is an important ingredient in its bread making operation.

When trying to reduce unacceptable mould levels in the compressed air lines at the plant, the baker’s process engineers discovered that the compressed air used to inflate bread bags and blow away the grains after the slicing process was also injecting mould spores drawn in by the compressor. A 5-micron filter had been installed on the air supply, but this level of filtration does not stop mould spores.

To solve the problem, a series of three filters were added to the compressed air supply - a particulate filter to remove water and large particles, a 0.01-micron coalescing filter to eliminate the spores and other ultrafine particulate, and a vapour-adsorbing filter to remove any oil or hydrocarbon vapour.

After adding these filters, lab tests confirmed that the mould spore count has been significantly reduced, extending the bread’s shelf life. This three-filter solution is now being evaluated as a standard for all machines across the company’s global baking facilities.

Ascomation Pty Ltd Contact info and more items like this at wf.net.au/U904

www.ProcessOnline.com.au

CASE STUDY

CAPS cuts Kilcoy’s costs The Kilcoy Pastoral Company (Kilcoy) has drastically reduced energy expenditure in its facilities in Queensland by refurbishing existing plant and installing new compressor equipment supplied

by Compressed Air and Power Solutions Australia (CAPS).

Kilcoy was formed in 1953 to supply local butchers and, since that time, has grown to be one of the largest integrated beef processors in Australia. Each year, more than 260,000 head of cattle pass through the company’s facility located 100 kilometres north-west of Brisbane.

Kilcoy sells meat to the domestic Australian market and also supplies its processed beef to 20 international markets, through its accreditation with AUS-MEAT as an approved exporter. The company is also a major employer in the region of South-East Queensland around the town which gave the company its name.

In 2011, a full energy audit of the Kilcoy plant was conducted

by Energy Efficiency Services (EES), a business division of CAPS Australia. Compressed air is responsible for 10-15% of industrial electricity use nationwide. Analysis of the audit results indicated there were considerable savings to be made by ensuring the compressed air systems were energy efficient.

According to John Pears, Queensland Sales Engineer for CAPS, an Ingersoll Rand Nirvana R160ne-A compressor was selected to achieve this objective. The system supplies the compressed air for the meat processors, pumps and tools, in addition to the packaging lines.

The Nirvana R160ne-A compressor features a variable speed drive coupled with a controller with easily adjustable operating parameters, onboard diagnostics and a built-in energy savings calculator. The unit also utilises a coolant curtain to reduce energy consumption by injecting atomised oil into the compressed air stream, significantly lowering the energy required for compression.

The Ingersoll Rand premium efficiency packages that are supplied with Nirvana compressors allow customers to utilise the full potential of VSD compressors through the use of two-stage airends. These deliver up to 15% more air than a single-stage compressor while consuming the same amount of

32 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

energy. Models in the Nirvana range are supplied with a hybrid permanent magnet (HPM) motor which provides high reliability and efficiency with unlimited starts/stops and constant pressure control. The compressor also has a ‘soft-start’ facility that allows the compressor to conserve energy by shutting down instead of running unloaded.

Dean Goode, Kilcoy Chief Executive, explained that the upgrade of its air compressor system was part of the processor’s ongoing program to improve its performance and reduce plant carbon emissions. The commissioning of new compressors, along with the installation of new refrigerated dryer and additional filtration systems was the largest contributing factor in the company’s energy cost savings. “Even though the average plant compressed air usage has increased by about 14%, there has been an average power reduction of 15% due to the improved compressor technology utilised,” Goode said.

“We’re proud of our reputation and have worked hard to improve our sustainability,” Goode added. “This upgrade is part of a continuing series of improvements aimed at delivering world-class environmental operations.”

Quentin St Baker, National Manager of EES, said the Kilcoy upgrade not only substantially boosts performance, but will also help to improve equipment life span and eliminate production downtime. He estimated that the resulting air compressor energy savings would exceed 40% and maintenance costs would be reduced by approximately 30%.

Kilcoy secured funding via a federal government Low Carbon Grant arranged through Origin Energy. “Low Carbon Australia’s finance covered the up-front costs of upgrading equipment which meant that our client could start benefiting from resulting energy efficiencies sooner,” said St Baker.

Kilcoy’s Goode said the energy savings from the compressed air upgrade would probably recoup the company’s investment within four years.

CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/U787

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NEW PRODUCTS

RUGGED RFID SYSTEMS Siemens is strengthening its RFID range in the UHF range with a range of products including antennas, a mobile reader as well as heat-resistant, compact data carriers in the Smart Label format, suitable for harsh environments including logistics, material handling and, increasingly, in production.

The Simatic RF640A antenna operates using circular polarisation, while the Simatic RF642A uses linear polarisation - both with a dimension of 185 x 185 x 45 mm. Depending on the reader used, the range of these antennas can be up to four metres. Meeting the requirements of protection IP67 and designed for operating temperatures of -25 to +75°C, these antennas are suitable for indoor and outdoor applications.

The Simatic RF680M mobile RFID reader includes a colour display with VGA resolution (640x480 pixels) and an ergonomic keypad. With improved readability and single-handed operability due to the rearrangement of keys, the reader has an increased transmit power (500 mW ERP), an improved CPU performance (624 MHz) and expanded memory (1 GB Flash and 256 MB RAM). The programming interfaces allow the customer to create their own RFID applications for the mobile reader, and can easily be integrated into existing IT networks and infrastructures using the standard Windows CE operating system.

The Simatic RF680L Smart Label RFID data carrier can tolerate one hour at temperatures of up to 220°C or six hours at temperatures of up to 200°C, suitable for demanding industrial applications such as painting lines and other high-temperature applications.

Siemens Ltd Contact info and more items like this at wf.net.au/U635 bread ad 18wx135

23/8/13

4:46 PM

Page 1

SAVE AT LEAST

OF OIL USE

30%

STOP MISTING STOP OVER-SPRAY T

he New AutoJet® Pan Oiling System from Spraying Systems Co, now applies oil to pans with even greater precision.

Get a constant spray of droplets around the interior of the pan Control the volume of oil, per pan cavity Monitor temperature and adjust the flow automatically Spraying Systems’ adjustable height precision spray guns, are mounted in a fully-enclosed housing.

They produce evenly-distributed drops and reduce misting and overspray by 80-90%.

Reduce waste; reduce excess cleaning costs; eliminate oil buildup and added heating costs, with the all new AutoJet® Pan Oiling System – built to Australian Standards.

Automate your pan oiling process by talking to the experts in spray technology for baked goods.

Spraying Systems Co. PTY LTD CALL THE EXPERTS 7 Sara Grove, Tottenham 3012 Victoria • Ph: (03) 8378 4100 • Fax: (03) 9315 3223 • sales@spray.com.au • www.spray.com

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1800 662 508

SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

NEW PRODUCTS

ALUMINIUM TWO-STAGE HELICAL BEVEL GEAR UNITS For hygienically demanding applications, NORD Drivesystems supplies aluminium two-stage helical bevel gear units in five sizes with a maximum torque of 660 Nm that are easy to clean.

The washdown design is based on smooth inclined surfaces, and

SCADA SOFTWARE UPDATE

has transitions with large radii without dead spaces and requires no

InduSoft Inc has released Service Pack 2 (SP2) for its

assembly covers. Cleaning liquids wash off easily and completely from

InduSoft Web Studio 7.1 software. SP2 provides native sup-

the surfaces, which also remain cooler than those of conventional

port of HTML5 screens and animation for multiple devices

drives due to the special construction.

and platforms, including Safari and Chrome browsers.

The design is suitable for use in the food industry and complies

InduSoft Web Studio lets users create screens once

with international guidelines and standards such as EHEDG, ANSI/

using the standard screen editor and then deploy these

BISSC and ANSI/NSF. If required, the gear units

screens across multiple operating systems, including iOS

can be fitted with double shaft seals. They can

and Android. Instead of waiting months for screens to

be ordered as open or closed frame versions

be developed for their device, InduSoft Web Studio 7.1

with hollow or solid shafts.

users can now instantly access screens on their various

Designed according to the

handheld devices via the Studio Mobile Access interface.

proven Unicase principle,

Another important addition is the support of native

the housings are torsion

shapes such as lines, rectangles, polygons or ellipses.

resistant and withstand high

Along with linked pictures, animations and active objects

mechanical stress. With the

such as buttons, check boxes and more, these features

optional NSD tupH surface treatment, they

render the screens for handheld devices to appear much

become highly resistant to corrosion as well as

like those of on the larger displays commonly found on

acids and alkaline solutions.

NORD’s NSD tupH sealed surface conversion system is not a

PCs. SP2 also supports a wide range of images (BMP, PNG, JPG, etc) and animation capabilities.

coating, which means that no layers can peel. Instead, the process

SP2 also provides built-in troubleshooting tools for the

transforms surfaces with up to seven times the hardness of the base

native VBScript editor. These tools, such as breakpoints

aluminium material. Thereby, the housings acquire robustness and

and variable watch lists, make debugging much easier.

durability qualities that are similar to stainless steel versions, while

Breakpoints can be created for global procedures, script

remaining lighter and more economic.

tasks, graphic scripts and screen scripts. This lets users

In addition to food industry processes, the gear units are also

debug a section of code and review the result, instead

suited to conveyor systems and hoists, especially in applications

of being forced to debug the entire code. Users can

where geared motors have to be moved and their light weight

also step through their VBScript code one line at a time

becomes essential. All gear units can be combined with suitable

by using the Step Into, Step Over and Step Out tools.

smooth-surface motors from NORD or other manufacturers.

Dominion Electronics

NORD Drivesystems (Aust) Pty Ltd

Contact info and more items like this at wf.net.au/U913

Contact info and more items like this at wf.net.au/U872

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NEW PRODUCTS

GAS ANALYSER CALIBRATION RIG The Michell Instruments PCR portable calibration rig is a mobile gas blender using premium mass flow controllers housed in a tough transport case that can be used for gas analyser calibration with a large variety of applications and analysers. It can mix two or three gases from air, oxygen, nitrogen, carbon dioxide, methane and hydrogen, and is easily controllable so that the perfect blend can be achieved for the application.

Provided the user has the appropriate gas cylinders available, it is possible to ‘factory’ calibrate an analyser such as the company’s XTP601. For example, an analyser range of 0-10% O2 in N2 could be calibrated with synthetic air and N2.

A field calibration of an analyser can be carried out in under one hour including set-up time.

For a complete factory calibration, with multiple calibration points (to change the range/background/both), four hours would be all that is required. These timescales represent a minimal downtime compared to the alternative of sending the instrument away for calibration.

Although the unit is designed for field calibrations, it can also be used in a laboratory to mimic changing process gases for research work.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/U487

PRESSURE SENSOR WIKA now offers updated options with its O-10 OEM pressure transmitter. Under the model designation O-10 (5), the instrument is available with a five-fold overpressure safety and resistance to condensation.

The overload capacity is mainly aimed at applications in the market segments of water supply and irrigation systems. It protects the pressure sensor from possible damage from the water-hammer effect that fast-switching valves can cause.

In the near future, the O-10 pressure sensor will also be available with a condensation-resistant housing. This prevents the formation of condensation in the instrument, which can occur where there is a distinct difference between the fluid and the ambient temperature.

These options increase the durability, and thus the service life, of the O-10 pressure sensor in critical applications.

WIKA Australia Contact info and more items like this at wf.net.au/U636

www.ProcessOnline.com.au

SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

NEW PRODUCTS

ETHERNET CONFIGURATION TOOL RUGGED IPAD CASE AND KEYBOARD The iKey StreetCase is designed to instantly transform an iPad into a rugged laptop. With the click of a button, an iPad easily locks into the durable ABS polycarbonate case, giving the user the protection of an industrialgrade solution at a fraction of the cost. When closed, the StreetCase fully shields the iPad from drops, vibration and extreme temperatures. The case can even be submersed in water without causing harm to the tablet.

Moxa’s MXconfig is a software utility for configuring and deploying industrial network devices. It can be used with a wide range of Moxa industrial ethernet switches, and supports a broad range of features well suited for industrial applications, including fast group configuration and deployment, link sequence detection, configuration overview and documentation, and user-privilege settings.

The product has an integrated Bluetooth-compatible keyboard that is completely

By being able to deploy the same con-

sealed to withstand the elements. With three levels of red LED backlight, it can

figuration settings, including IP addresses,

always be seen clearly, even during night use. The keyboard has a micro USB

redundancy protocols and VLAN settings,

charging port built into the case, and can be used for two months on a single

across multiple Moxa switches,

charge. Along with a fully QWERTY layout, the product includes iPad-specific hot keys for media controls, search function, home screen and locking.

Designed with corporate and government users in mind, the product has an integrated VESA pattern on the bottom, which easily fits into existing vehicle mounts. It is also available with an optional quick-release mount that allows the user to go from in-vehicle use to the field in seconds.

The product has adjustable internal rails that can be locked into multiple viewing angles. In addition, the case can be locked to prevent theft of the iPad. When in the field, it can easily be carried with the robust handle or optional shoulder strap.

Interworld Electronics and Computer Industries Contact info and more items like this at wf.net.au/U791 MXconfig significantly saves set-up time and eliminates the inevitable configuration errors

COMPRESSORS

that arise when configuration is done manually.

Ingersoll Rand has expanded its contact-cooled rotary screw air compressor

Configuration duplication is also available for

line with the R-Series 55-75 kW range. The range is available with either fixed-

users to easily copy the configuration from one

speed or Nirvana variable-speed drives at capacities up to 3.23-13.56 m3/min.

device to a large number of other devices.

The R-Series machines are equipped with the Xe-Series controller, which

To ensure network availability while configur-

features a high-resolution colour LCD. The monitor provides immediate access

ing VLAN or redundancy settings, MXconfig

to all vital compressor data and settings. The controller also permits remote

supports link sequence detection, which allows

control of the compressor from any PC, tablet or smartphone via the

users to prioritise devices according to physi-

internet and can send automatic email notifications of

cal distance, ensuring that each device will

trips and warnings to designated personnel.

be configured completely and in the proper

The integrated Total Air System (TAS) dryer and filtra-

order. Configuration files can also be batch

tion option provides clean, dry air in a single package,

exported or one-to-all imported for future

reducing installation costs while allowing single-point

backup or quick reinstallation.

maintenance and monitoring for the whole system. The

MXconfig provides three levels of privilege

Total Air System option comes with refrigerated dryer

security - Admin, Supervisor, and Operator -

technology and a high efficiency coalescing filter to deliver

giving users the ability to set and manage

ISO Class 1-4-2 quality air. The TAS option also uses a

critical functions that can have a large impact

3-in-1 heat exchanger, which improves energy efficiency and

on network performance, such as general

lowers operating cost when compared to traditional stand-alone dryers.

network settings, VLAN settings, redundancy

Progressive Adaptive Control (PAC) protection is an integrated, intelligent

protocols, and factory defaults, with the added

system that monitors filtration, ambient temperature and other parameters and

versatility significantly enhancing management

adapts the operation of the compressor in order to reduce energy consumption,

flexibility and security.

lower noise and increase uptime. V-Shield technology is a configuration using

For more details and to download the MX-

stainless steel pipes, durable metal-flex hoses and a vibration isolation system

config software for free, visit Moxa’s website at

to eliminate possible leaks. Sequential cooling uses a centrifugal blower, which

http://www.moxa.com/product/MXconfig.htm.

uses much quieter cooling fans to consume less energy.

CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/U265

36 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

Madison Technologies Contact info and more items like this at wf.net.au/U227

www.ProcessOnline.com.au

NEW PRODUCTS

LARGE GUIDE TROUGH The ‘guidefast’ guiding trough from igus has been devel-

REGULATOR

oped especially for a lateral mounting to standard carriers

The Rotork Fairchild Model 11 is a regulator

of industry and hall cranes, and the modular design and

which offers high accuracy for applications

a reduced number of components significantly reduce the

with very low output pressure ranges.

installation time.

Available in five different ranges, the

The modular design simplifies the work of the installer

regulator provides sensitivity of 0.05″

with every step including the use of special brackets that

of water column (1.25 mm WC) for easy

are mounted via screw/thread or welding bolts, which allows simple vertical fine-adjustment. The static cables can be directly fixed to the integrated strain relief of the bracket - considerably simplifying electrification and additional fixings (eg, cable clips or hose clamps become redundant).

The energy chain is directly inserted into the guiding trough including cables, and through the cable supply, the installer can easily connect feeds wherever the situation requires it. The use of prefabricated bore patterns accelerates the installation since time-consuming measuring, drilling or cutting is now unnecessary.

The trough is available in different materials such as

setting and high repeatability.

The model delivers 24 SCFM (28 L/s) flow capacity and is said to be well equipped to handle difficult applications such as leak detection systems, tank blanketing, air and gas sampling systems, analytical equipment, test stands, and soil and sample testing.

Where envelope size must be minimised the regulator is a suitable solution, as its diaphragm diameter is engineered for optimum performance in a compact package. Tamper proof, screw or standard knob actuation alternatives provide versatility and ease of use and with nitrile or optional fluorocarbon

galvanised steel, stainless steel or black powdered steel

elastomers, the regulator is suitable for many environments.

versions.

Rotork Australia

Treotham Automation Pty Ltd

Contact info and more items like this at wf.net.au/U804

Contact info and more items like this at wf.net.au/U528

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SEPTEMBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

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

TCO: UNDERSTANDING ITS ROLE IN PROCESS AUTOMATION

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

I

f you are an operator in the resources industry, it is undeniable that the cost of doing business in Australia and New Zealand is rising. A higher price for labour, more taxes and greater regulation have all increased the cost of extracting resources from the ground. At Honeywell, we know that many of our clients are facing tighter budgets, with a need to return operating costs to levels seen before the global financial crisis.

For businesses, staying ahead in this environment clearly means doing more with less. It’s a careful balance; you must adopt strategies to drive down costs but at the same time increase yields and meet the rapid pace of market pressures. As a result, operators are not only looking to increase the efficiency of their production process, but also reduce the long-term total cost of ownership (TCO) of automation assets.

A concept first coined by the IT industry more than 20 years ago, TCO has become more important than ever for industrial organisations of all sizes. But unlike with traditional IT systems, determining TCO in the process automation field has unique requirements. It must account for long and variable life cycles, necessary reliability, platform switching costs, possible disruption to operations when changes are made, and the costs of training staff so users can be proficient with new equipment. It needs to consider risks and efficiencies in process applications, the value of flexibility and scalability, and also align with strategic process project goals.

For plant owners, it’s just as important to recognise what TCO doesn’t do as it is to understand its primary function. TCO does not calculate the overall value of a technological purchase, or return on investment. Rather, it shows manufacturers how much they can expect to spend during an

Art Director/Production Manager

automation asset’s full life cycle. It only looks at the cost side of the equation.

In order to avoid complications brought about by shorter life cycles, plants need an approach to TCO which closely aligns the automation life span with that of plant process assets. Focusing on product life cycle issues, for instance, can help users utilise legacy control hardware and software alongside newer distributed control systems.

By looking at the total value of ownership (TVO), plant owners can incorporate total benefits attained (TBA) such as increases in throughput, yield and productivity and balance this with the total cost of ownership (TVO = TBA – TCO). And by evaluating TCO in relation to TBA and TVO, users can migrate legacy control assets at their own pace. Additionally, facilities can remain with certain platforms for longer periods of time.

In many ways, TCO has become just as critical to plant operations as having the right instrumentation, process control system, advanced process control applications and manufacturing execution systems to create an interconnected facility that brings the right information to the right people. Maximising the life cycles of all these systems is the most important factor to lowering TCO and truly impacting the bottom line.

Julie Wright Art/Production Tanya Scarselletti, Colleen Sam, Jeanette Teuma Circulation Manager Sue Lavery circulation@westwick-farrow.com.au Copy Control Mitchie Mullins Advertising Sales National Sales Manager/NSW/QLD Nicola Fender-Fox ph: 0414 703 780 nfender-fox@westwick-farrow.com.au VIC/SA/WA - Lachlan Rainey ph: 0402 157 167 lrainey@westwick-farrow.com.au NZ - Gemma Burr ph: 0800 44 2529 gburr@westwick-farrow.com.au USA - Huson International Media East Coast ph: +1 212 268 3344 West Coast ph: +1 408 879 6666 ralph.lockwood@husonmedia.com UK - Huson International Media ph: +44 1932 56 4999 gerryb@husonmedia.com Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application.

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

March 2013 total CAB audited circulation (Aust + NZ) 6,984 readers (79% personally requested)

Garry Mahoney is the pacific director of Honeywell Process Solutions. He has over 35 years of experience in engineering, with a specific focus on instrumentation and process automation.

Garry joined Honeywell Process Solutions in 1981 and has held a variety of positions during this time, from support to project delivery and business development.

38 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2013

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20–22 NOVEMBER

Melbourne Convention and Exhibition Centre In conjunction with the ARCIA Industry Gala Dinner

Government • Enterprise • Transportation • Utilities • Mining • Public Safety • Security

Comms Connect delivers more for 2013 Comms Connect – formerly RadioComms Connect – returns to Melbourne’s MCEC this November to deliver vital information to the mission and businesscritical communications communities – the users, the dealers and industry.

Help create safer, smarter, more secure environments, where available information is gathered and then distributed to those that help protect us and our environments when, where and how they need it most.

With almost 100 exhibitors, 50 speakers, 6 ALL NEW training workshops, panel discussions, roundtables and more, Comms Connect 2013 has the answers to your communication infrastructure and system requirement questions.

Focus for 2013’s half-day training workshops:

• Mobile broadband for critical communications users • Infrastructure and towers • Advanced radio over IP • In-building distributed antennae systems (DAS) • Tetra network and design • Implementing a digital radio system

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Visit the website where this year’s speakers, topics and full training workshop outlines can be found!

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