What’s New in Process Technology Sept 2012

0912

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY SEPTEMBER 2012

CONTENTS

The Prosonic Flow B200 is an innovative new development to specifically address the measurement problems associated with saturated low-pressure gas flow streams.

Traditionally, other flow metering principles have not been able to provide the desired

4

Australia's mining thirst

level of measurement performance (accuracy,

The gas to liquid solution

turndown and stability) over the range of

8

New products

10

Hot products online

gas. Often these meters are intrusive, exhibit

24

Redefining the SCADA architecture

The prevalent issues are low pressures, low

Distributed architecture helps utilities support a more intelligent grid

velocities, variable gas composition, particu-

38

As I see it Accelerating innovation with smaller teams

process conditions found in methane-related applications such as biogas and coal seam pressure loss and are maintenance intensive.

lates, condensate and corrosion.

The B200 addresses these issues by taking proven transit-time ultrasonic spool-piece technology and optimising it with dedicated transducers and intelligent signal analysis and computations. But what is a world’s first is the ability to determine percentage methane content via sound velocity and integrated temperature measurement. This enables vastly improved measurement certainty with varying gas composition and makes it immune to wet gas conditions.

The multivariable transmitter comes with a 2-wire loop-powered supply and can provide other useful variables such as gas temperature, methane fraction, energy flow, and totalised heat energy - making it suitable for process monitoring and gas engine feeds.

The B200 operates in temperatures up to 80°C and pressures up to 10 bar, and can be installed in line sizes from 3″ to 8″. Accuracy of volume flow is 1.5% of reading and accuracy of the optional methane measurement is 2% absolute. The B200 also has IECEx approvals.

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Communication is via HART or Profibus PA. Endress+Hauser Australia Pty Ltd

AUSTRALIA’S MINING THIRST THE GAS TO LIQUID SOLUTION

SS Shastri, SF Kamper, TR Sonigra, TR Hill and J Beales, GHD Pty Ltd

© iStockphoto.com/Darryl Peroni

The iron ore industry in Western Australia consumes in excess of a 3 million litres of diesel each day. This diesel is delivered to the mine sites either by rail up to the site load-out or by a combination of rail and road. The use of mine transport corridors for transport of fuel not only adds significant costs, but also has a considerable safety impact.

4 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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A

ustralia is currently heavily dependent on road transport for the movement of goods across the country. The primary fuel that drives this aspect of the economy is diesel.

Diesel, too, is the lifeblood of the mining industry from providing power to facilities and accommodation to heavy haulage and everything in between. It is predicted that diesel fuel usage will continue to grow with the global demand for Australian resources and domestic consumption.

Australia currently imports about a third of its liquid fuels; a continued increase in fuel imports is neither sustainable nor acceptable. It may be argued that Australia’s access to international markets suggests that energy security may be good; however, Figure 1 shows that Australia’s self-sufficiency is reducing. There is therefore a real opportunity to grow local industry and increase energy security.

Australian natural gas reserves (including coal seam methane and shale gas) are significant and new discoveries are being made. Gas reserves close to the coast and major infrastructure hubs can be transported and processed relatively cheaply compared to LNG or other products. Stranded gas reserves on the other hand are stranded by virtue of being economically too far away from gas processing and transfer infrastructure.

While some new shale and tight gas locations are potentially stranded, many of these reserves are close to or overlap some of the active mining tenements. In Western Australia, for instance, potential shale gas reserves are located close to the Pilbara where most of Australia’s iron ore is being produced.

With the iron ore industry in Western Australia consuming in excess of 3 million litres of diesel each day, there is a case for the use of this stranded gas not only to meet the power requirements of the mines located in their neighbourhood, but also the significant liquid fuel requirements of the mines. This can be achieved through small-scale conversion of natural gas to diesel fuel through the well-understood gas to liquid (GTL) process.

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Location of mines and shale gas reserves Australia has a number of shale and tight gas basins such as Cooper, Amadeus and Georgina, among others. The Amadeus Basin is the closest to the Pilbara mining infrastructure, and companies are beginning exploration activity in this basin. A portion of the Amadeus Basin has already been explored and there is a pipeline to NT. Other shale and tight gas deposits are to be explored (eg, Central Petroleum’s reserves).

Central Petroleum’s stake in the Amadeus Basin, for instance, has an estimated 26 trillion cubic feet of gas - a potentially significant resource.

The iron ore mines are located almost midway between the coast and the shale gas basins to the east. Until the global supply of LNG exceeds demand, economics favour export over domestic use. Existing gas processing infrastructure on the coast may have insufficient capacity to process additional gas. Should processing capacity exist in infrastructure on the coast, the cost of laying a new pipeline across several active mine sites may be cost prohibitive.

Gas geographically close to Pilbara mine sites increases the potential for commercial exploitation by both the miners and gas producers.

Gas to liquid process Gas to liquid refers to the conversion of natural gas to a hydrocarbon liquid fuel (crude) that can be converted to diesel or other final fuel.

The GTL process is an established process with a long history. Figure 2 depicts the process. Natural gas (primarily methane) is reformed with steam to produce synthesis gas (molar ratio of hydrogen to carbon monoxide of 2 to 1). The synthesis gas is then converted by Fischer Tropsch (FT) reaction to synthetic crude oil that is further refined to produce middle distillates or diesel.

The details of the Fischer-Tropsch process are covered by a significant body of knowledge spanning several decades that is available in journals and books.

SEPTEMBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Research

Figure 1: Australian fuel self-sufficiency (Source: ACIL Tasman Report, 20081) Figure 2: Typical GTL process.

There are a number of current research projects aimed at reducing the costs of the GTL process. For example, CSIRO in Australia has research projects aimed at reducing the energy usage in the synthesis gas formation step of the process and aimed at finding a catalyst to target diesel production over other hydrocarbon formation. Both projects (if successful) will reduce the costs of the plant2.

Proposal and technical feasibility Demand rationale In Australia, 40 companies in the mining sector consumed 52.5 PJ of diesel equivalent in 2008-093. The heating value of diesel ranges between 44 and 48 MJ per kilogram and density ranges from 820 to 860 kg/m3. Assuming a mid-value for heating value and density, this energy represents 8.9 million barrels consumed in 2008-09 for mine production, including 342 million tonnes of iron ore in Australia. The current production of iron ore is 408 million tonnes and simple extrapolation would indicate a diesel consumption of about 10 million barrels. However, personal communication with a senior mine executive indicated that 1 million litres of diesel is consumed each day to meet a production target of nearly 15% of overall iron ore output (this is consistent with published literature).

This equates to about 42,000 barrels of fuel consumption a day. As no mining operation will provide exact data on fuel consumption, it is reasonable to assume that diesel consumption will be somewhere between 10 and 15.3 million barrels each year.

Over 2011, the base cost of diesel has hovered between 70 and 80 cents per litre; with shipping costs this increased to between

$1.20 and $1.30 per litre. With other additions, the final retail price of diesel (including all costs and taxes) varied between $1.30 and $1.605. It is understood that this final retail cost is based on import pricing parity, and large mining customers and the agricultural sector could get discounts of the order of 30%. Therefore, cost at source (gate) is assumed to be $1.45 (average of high and low retail) discounted by 30% to $1.015 a litre. The actual transportation costs to the point of use, sometimes several hundred kilometres away, are not known. The past year has seen the steady increase in fuel prices, and in early December 2011, West Texas Intermediate crude was selling at around $100 a barrel.

The current cost of diesel in terms of energy is about $27 per GJ (this may or may not include transportation costs to site and is the gate price). The cost of gas delivered to the Sino Iron Ore project, for example, is between $11 and $13 per GJ6.

Thus inclusive of pipeline costs, cost of gas appears to be between 2 and 2.5 times less than that of diesel.

Safety rationale The delivery of diesel fuel to the point of use often requires the use of other infrastructure - road and rail primarily. The use of road infrastructure implies sharing of roads with other users, light vehicles, heavy haul trucks (some up to five cars) and sometimes dump trucks. Segregation of traffic is not always possible and in a mine environment a major hazard is the non-segregation of traffic that could lead to vehicle interactions. From a rail perspective, the need to send a fuel rake on a shared line is in itself not a problem as most rail operations in Australia are very tightly regulated; however, it does bring in

6 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

a scheduling constraint, as most mining operations are poised to grow significantly.

Transportation rationale The scheduling of fuel transport either by rail or road reduces overall capacity available for resource transfer; and based on current expansion plans, it appears that existing infrastructure will be used to near capacity.

Large operators such as Rio Tinto and BHP Billiton have gas supply infrastructure to some of their facilities; for example, the Goldfields Gas Transmission (GGT) pipeline delivers gas to Rio’s operations in Paraburdoo.

This gas is presently consumed to produce power for the mines and local communities.

Environmental benefits There are significant environmental benefits to producing GTL (synthetic) diesel close to the point of use. The environmental impact of transporting diesel from Singapore to Australia, and then onwards to the mining areas, will be significantly lessened. Catalyst from the FT process plant is recyclable and the resulting water product can be used for irrigation or within the mining process.

GTL diesel will have a better environmental and performance profile than conventional diesels derived from crude oil. The diesel is characterised by a high cetane number (at least 70), low sulfur (less than five parts per million), low aromatics (less than 1%) and good cold flow characteristics (less than 5-10°C).

Figure 3 is taken from the Hobbs report to the Southern States Energy Board, Georgia titled American Energy Security7.

Synthetic GTL diesel is compatible with existing fuel distribution infrastructure. In addition, GTL diesel can be used in both current and envisaged future diesel engines, along with their exhaust gas after-treatment

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Research

Figure 4: Environmental comparison of synthetic and conventional diesel fuels.

Figure 3: Global iron ore exports (Source: Ocean Equities, 20114). technologies; meaning few (if any) modifications to existing equipment and infrastructure are required to realise the benefits.

Cost analysis A typical operation would consume about 1 million litres of diesel each day (~6000 barrels) and some of the larger operations would consume a little over 1.6 million litres of diesel each day (~10,300 barrels); therefore, a gas to liquids facility to produce 10,000 barrels of diesel per day is considered for this analysis.

Based on a material balance (Marano and Ciferno, 20018), a 17,000 barrel per day GTL facility will produce approximately 10,000 barrels of diesel per day.

CAPEX Pacific GTL’s proposed 17,000 barrels per day was estimated to cost $1.5 billion in 2010, and was to have been located in Brisbane. Assume therefore that this size plant built in the Pilbara will cost $2.0 billion. With constant advances in catalyst technology and the use of clever modularised design and construction it would be hoped that this cost could be reduced.

Factors that need to be taken into consideration are lead times required for design and construction and the need for speed of delivery to match planned growth. It may be worth considering off-the-shelf technologies that would be suited to a range of production capacities ranging from 200 to 5,000 barrels per day.

OPEX A 17,000 barrels/day GTL plant would require about 9 TJ/day of gas; based on pricing for which data is available ($11/GJ) this would equate to $100,000 a day for gas, or $10 per barrel of diesel. The cost of producing the diesel is estimated (internal calculations) to

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be about US$23 a barrel, which equates to about 15 cents per litre or, based on 10,000 barrels a day, equals $230,000 per day.

The current cost of purchasing commercial diesel at gate prices is estimated to be about US$1.6 million a day (based on 10,000 barrels a day at $1.015 per litre) and over a year US$584 million. This cost does not include the cost of transport to site, safety costs, scheduling costs and additional infrastructure required such as large tank farms and distribution facilities. For the purposes of the calculation, an additional 10c per litre have been added, actual data is required to improve this accuracy.

Return on investment The cost analysis considered the construction of a 17,000 barrels per day gas-to-liquid facility. The model assumed three years for the design and construction of the facility.

No credit is taken for either electric power produced by the GTL process or for the LPG/gasoline that is produced. For ease of calculation (as this indicative only), the price of fuel and operating costs remain unchanged over 10 years. Under these conditions the break-even point is reached 10 years from the time the funds are sanctioned. At the end of 20 years, the IRR is 10%.

The GTL process produces other saleable hydrocarbon products as well as diesel. The potential revenue from these has not been taken into account in the economic analysis for this article; it would be expected to have a positive impact on the returns from the project, however.

The construction of a GTL facility as a collaborative venture between a large operator and a stranded gas developer could result in cost savings of nearly 85% in actual fuel

costs and a positive return on investment in less than 10 years. When the significant amount of research into this technology begins to bear fruit, it is likely that the economic returns from the investment will be greatly increased.

References 1. ACIL Tasman, An assessment of Australia’s liquid fuel vulnerability, November 2008 2. CSIRO Report, Gas Processing and Conversion: fuel for Australia's future, http:// www.csiro.au/en/Outcomes/Energy/GasProcessing-Conversion-Fuel-Future.aspx, accessed 01 February 2012 3. Australian Government, Department of Energy and Tourism, EEO Case Study Analyses of diesel use for mine haul and transport operations, 2010 4. Ocean Equities African Iron Ore Sector Research 07072011, Iron Ore Sector update, downloaded 13 Dec 2011 from http://www. sundanceresources.com 5. http://www.aip.com.au/pricing/facts/Weekly_Diesel_Prices_Report.htm, fuel pricing details, accessed 8 Dec, 2011 6. ACIL Tasman, Gas prices in Western Australia, May 2010 7. The Southern States Energy Board Norcross, Georgia, American Energy Security - Building a bridge to energy independence and to a sustainable future, July 2006 8. Marano JJ and Ciferno JP, Life-Cycle Greenhouse-Gas Emissions Inventory for Fischer-Tropsch Fuels, Energy and Environmental Solutions paper for US Dept. of Energy, National Energy Testing Laboratory, June 2001.

GHD Pty Ltd Contact info and more items like this at wf.net.au/R118

SEPTEMBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

INTRINSICALLY SAFE PRESSURE CALIBRATOR The WIKA CPH65I0 is an intrinsically safe pressure calibrator. With an accuracy of 0.025% of span and various additional functions, this instrument is suited to a wide range of applications and, due to its ATEX approval, these also include hazardous areas.

The instrument is available with either one or two built-in reference pressure sensors. This allows 24 different measuring ranges of up to 700 bar to be covered.

In addition, the pressure calibrator accepts transmitter output signals (0-24 mA) and the ambient and medium

DATA ANALYSIS SOFTWARE

temperature (-40 to +150°C) is measured

National Instruments has announced DIAdem 2012, the latest version

by a resistance thermometer.

of the software tool specifically designed to help engineers and sci-

A pressure switch test func-

entists interpret and share data. Analysing and reporting time-based

tion completes the func-

measurement data presents unique challenges that DIAdem is claimed

tionality.

to overcome with an off-the-shelf solution. DIAdem is optimised to

Although it is multifunc-

operate on large data sets, includes engineering-specific analysis

tional, the robust instru-

functions, features a powerful drag-and-drop report editor and runs

ment is simple to operate

scripts for automating repetitive tasks.

using three keys. On the

DIAdem 2012 features an object-oriented VBScript API for reporting,

5-digit, backlit display, three

significantly reducing programming time and effort. Performance has

measurement parameters

been improved for reporting, especially for multi-page reports, and

can be displayed simultane-

new analysis functions. NI have also added the ability to check for

ously. The battery power supply

updates to DataPlugins within DIAdem, and updated DAC dialog boxes

is designed for at least 35 hours

make configuration of data-logging applications easier.

of operation.

Support has also been added for LIN and FlexRay databases, as

WIKA Australia

well as scalable background images for 2D charts.

Contact info and more items like this at wf.net.au/Q669

National Instruments Australia Contact info and more items like this at wf.net.au/Q335

INDUSTRIAL TABLET PC Phoenix Contact has available a 13.3″ touch screen industrial tablet PC. The basic version allows integration into an existing network via WLAN according to IEEE 802.11 a/b/g or via Bluetooth Class 1 and Class 2. With an optional expansion, it can also connect to a UMTS network or receive GPRS signals.

The tablet PC is equipped with a 1.6 GHz Z530 Intel Atom processor or with a dual-core processor clocked at 1.2 GHz for applications demanding high computing power.

Its rugged casing conforms to protection class IP65, making the tablet suitable for both indoor and outdoor use. The tablet is lightweight and can be carried using hand straps or a shoulder harness.

The PC has watertight USB, audio and RJ45 interfaces. It can be retrofitted with a barcode scanner or RFID wireless identification system for managing inventories. It uses two lithium-ion rechargeable batteries, which Phoenix claims allows for flexible operation independent of a power supply.

The tablet’s zero power management minimises battery discharge while in idle state.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/Q492

8 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH DOUBLE BLOCK AND BLEED VALVE The Noshok 3070 Series is a double block and bleed valve with redundant isolation valves and a dedicated vent valve.

AMS Instrumentation & Calibration Pty Ltd

>

WF.NET.AU/R067

SAFETY ENCODERS These encoders fulfil the requirements of IEC 61508, EN 62061 (SIL CL3) and EN ISO 13849 (performance level e).

Plant Control & Automation

>

>

WF.NET.AU/R020

UPGRADED CONTROLLER An extension signal module has been released for the MultiCell 8619 as a signal input board that can be used for direct connection of additional input devices.

B端rkert Fluid Control Systems

WF.NET.AU/Q827

PNOZcompact safety relays monitor the basic functions of emergency stop or safety gate, providing maximum safety

>

up to Performance Level (PL) e or SIL 3.

Pilz Australia Industrial Automation LP

WF.NET.AU/R155

10 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

>

COMPACT SAFETY RELAY

DAQ SYSTEM National Instruments has announced the latest stand-alone NI CompactDAQ system, a high-performance embedded measurement and logging platform.

National Instruments Australia

WF.NET.AU/R077

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PNEUMATIC+HYDRAULIC

PRODUCTS

3ECURE #OMMUNICATION -ADE %ASY ;jaa"higZc\i] GZbdiZ 6XXZhh GZVYn ^c &* B^cjiZh

COMPACT VALVE AND BLOCK SOLUTION

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Burkert has released a modular valve and block package

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designed to help build systems quickly and easily. The Inox

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system incorporates an all stainless steel pneumatically actu-

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port channels. The ports are drilled open in accordance with

ated valve, and standard block modules with eight standard block channel design, bolted together, and valves screwed in to complete the block system. Strainers, check valves and sensors are easily included in block construction.

Inox block systems support media to 180°C, 16 bar and 600 mm 2/s viscosity and have high chemical resistance to process media including water, alcohols, oils, fuels, hydraulic fluids, salt solutions, alkali solutions, organic solvents, steam

A^c`BVcV\Zg <ViZBVcV\Zg

H^iZBVcV\Zg

and air. System configuration eliminates the use of elbows and t-adapters, and reduces connections to a minimum to avoid leaks and deliver high overall system performance relative to traditional block solutions.

Small footprint, flexible configuration and fast assembly make the systems suitable for manufactured blocks including

K^h^i i]Z lZW id hZZ i]Z HZXdbZV bdk^Z cdl# 9^hig^WjiZY Wn

temperature systems for injection moulding or die-casting tools, chemical dispensing in water or mineral processing, steam sterilisation systems, and any solution where high system capability and environmental integrity is necessary.

Distributing, collecting and mixing systems with individual valve flow of up to 2.4m 3/h are suited to Inox.

Individual Inox valves feature cast 316L stainless steel bodies with integrated, self-adjusting packing glands to ensure high media tightness over the complete service life.

The externally piloted valves have a compact design and

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12 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

are available with threaded, external threaded and welding connection ports.

Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/N923

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PRODUCTS

CONTROL VALVES

OIL-FREE CENTRIFUGAL COMPRESSOR The Viking Lite range of pneu-

Compressed Air and Power Solutions (CAPS) Australia has

matic directional control valves

released the Centac C1000 oil-free centrifugal compressor, which

is suitable for a wide range of

comprises the main compressor unit and at least

industrial applications. The range

three coolers mounted on a cast-iron frame.

can be specified in three different

The three coolers - two inter-stage

port sizes namely G1/8, G1/4

and one after-cooler - have been

and G3/8 and offers compact

oversized to provide greater

installation dimensions especially

resistance to fouling and also

beneficial for space-critical ap-

provide low CTD and pressure

plications.

drop to increase compressor

The range features dynamic bidirectional spool seals. Suit-

efficiency and reliability.

The key feature of these water-in-

able for pressures up to 10 bar in ambient temperatures of -10

tube coolers is accessibility and serviceability from both ends of

to + 50째C, underpressure radial expansion of the seal occurs to

the package. The C1000 also features heavy-duty, high-efficiency

maintain sealing contact with the valve bore. Delivering more than

motors and uniformed, hardened components for improved du-

10 million operating cycles, Viking Lite is claimed to offer short

rability and reliability.

changeover times and low changeover pressure. This means that

The vertically split arrangement of the design provides fast

general maintenance and service time can be considerably reduced.

access to major components of the compressor. If the cooling

Manufactured from anodised aluminium, the range offers a valve

tubes are blocked, the performance of the whole compressor

with good corrosion resistance in a smooth design. This eliminates

will be compromised. Cleaning the water tubes involves a simple

dirt-collecting pockets, thus making the valves suitable for a wide

process of removing the two end covers of the cooler to clean

variety of environments. Optimised to comply with the requirements

out any debris in tubes. The design also allows easier access

for component reliability in accordance with the EU machinery direc-

to all the components of the compressor, reducing maintenance

tive standards EN292-2 and EN983, the range is designed for use

and servicing time.

with or without supplementary lubrication.

The streamlined design simplifies installation of a C1000 into

In addition to single valve installation the valves can be installed

any industrial setting. In the fully enclosed model, all components

onto manifolds so that there is a common supply and manifolded

are mounted in an acoustic enclosure that only requires water,

exhausts.

power and air connections.

Parker Hannifin (Aust) Pty Ltd

CAPS Australia Pty Ltd

Contact info and more items like this at wf.net.au/Q855

Contact info and more items like this at wf.net.au/Q274

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SEPTEMBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

Murray Goulburn cuts carbon emissions with compressed air upgrade CompAir’s Quantima compressor system has helped Australia’s largest milk processor, Murray Goulburn (MGC), reduce costs and carbon emissions.

Murray Goulburn processes 37% of Australia’s milk supply and is the nation’s biggest exporter of processed food. It is committed to the environmental sustainability of its business and has a continuous development program in place to reduce its carbon footprint. This program, in conjunction with the availability of state funding towards the purchase of energy-efficient technologies, prompted MGC’s Group Maintenance Manager, Mark Gurney, to consider replacement options for the existing compressed air system at the company’s Leongatha plant in Victoria.

The company decided to implement a completely new system to s u pp l y a l l o f t h e fa c t o r y ’s compressed air requirements for both plant and packaging processes, including new compressor units, air supply pipes and dryers.

C o m p A i r Au s t ra l a s i a p u t forward a proposal for the new system that involved replacing the four existing compressor units with just one 300 kW Quantima compressor and leaving two units for standby air.

A detailed audit was taken before and after the installation and submitted to the state government, proving that the new installation has enabled MGC to meet its power reduction target with an overall energy saving of more than 35%.

“By combining the innovative Quantima compressor with all downstream equipment, including desiccant dryers and new air distribution pipes, we have been able to reduce pressure drops and air leaks dramatically,” said Gurney.

“Prior to the installation, our compressed air system was using 9.1 kW to generate each cubic metre of air per minute. Now, with Quantima, this specific power consumption has reduced significantly to just 6.12 kW/Nm3/min. In simple terms, we are now producing compressed air at best practice levels and with much better efficiency - to the effect it is now taking 33% less power for us to generate a higher air output.”

MGC has already realised CO2 savings of 1908 tonnes - equivalent to planting over 2805 trees or taking 440 cars off the road.

The Quantima saves energy through its Q-drive, a centrifugal compression assembly that consumes significantly less power than

14 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

conventional technologies. Q-drive’s rotor shaft is its only moving part, reducing friction contact that can result in energy losses and performance degradation over time. A variable speed drive allocates airflow according to plant demand to further save energy.

The Quantima has not only saved MGC energy, its predictive maintenance solution, Q-life, also saves on servicing costs. CompAir engineers monitor the machine’s performance remotely, moderating it where necessary to prevent a fault occurring or arranging a local engineer for remedial repairs.

CompAir had already been providing regular servicing to MGC’s plant, carried out by local CompAir engineers. Q-life also comes with risk-free, fixed price servicing, a solution which has saved MGC 64% on its service costs. Another bonus is that Quantima’s oil-free system negates the need for disposal and treatment of waste oil and condensate - and all the associated costs.

To further reduce energy consumption and the reliance on chilled water supply, MGC and CompAir are working together to design water cooling towers.

These will enable water to be taken straight into the process, which can be up to 8% more energy efficient than using a separate factory chiller to cool the mains water. The towers are projected to save another 71 kW of installed power, meaning a further 677 tonnes of CO2 savings each year.

MGC also has the requirement to use contaminant-free air.

With no gearbox and therefore no need for oil lubrication, the new compressor is also completely oil free, to guarantee air purity and eliminate the need for additional compressed air filtration.

Gurney is happy with the new system: “Instead of simply replacing one or two of our existing compressors, we chose to install a complete new system that would deliver a low cost of ownership, with the maximum energy savings possible. We are very pleased with the results.

“After only five months, the Quantima compressor has already delivered the energy-saving and carbon footprint reductions that we expected. Overall the project will pay back, pre-tax, in 22 months.”

CompAir (Australasia) Limited Contact info and more items like this at wf.net.au/R122

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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.

PNEUMATIC+HYDRAULIC

PRODUCTS

COMPRESSOR CONTROLLER Centac compressors are produced in a range of sizes and outputs that can deliver the large volumes of compressed air needed for many industrial processes. The latest controller for Centac’s centrifugal compressors is the Xe-145F, which has advanced remote communications and control features.

The Xe-145F has multiple connections - such as ethernet, service port, remote contacts or Modbus - allowing compressors to be remotely accessed and controlled from anywhere on a network, or even over the internet. Controllers can also be integrated into a DCS or other standard plant automation system. The web interface of the Xe controller makes it easy to adjust the configuration of a compressor installation, saving both time and effort. Compressor performance data can be captured and analysed quickly and effectively using built-in logging, graphing and performance monitoring capabilities. The Xe controller can send notification of system alarms and warnings via email or SMS. The control software helps reduce excess energy use by optimising partial load performance. The system automatically adjusts control parameters based on changing ambient conditions, thereby preventing premature compressor bypass and maximising turndown capability. By providing precise pressure control, inlet and bypass valves can be operated in harmony, thereby making a compressed air system more stable and reliable.

By including an optional Air System Controller (ASC), it is possible to integrate the Xe-145 controllers for individual compressors and automatically manage their operation from a central location.

CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/Q843

HYDRAULIC PISTON MOTORS The SH7V and SH7VR variable displacement hydraulic motors from Brevini Australia offer significantly improved performance than the previous H2V model, with very high power density and improved efficiency, even at low speeds.

Currently used in drilling rigs in Italy, China, USA and Japan, the SH7 108 and 160 are now field proven for use in heavy-duty transmission applications. Featuring a displacement ratio of 5:1, there are three displacements available from 75-160 cc/rev, with a continuous pressure of 430 bar and peak of 480 bar.

The motors are of bimetal barrel construction, with seven single-piece pistons made from 31CrMoV12.

A special carbon coating is used to reduce friction and is sealed with a Viton shaft seal. The 28° bent axis angle does away with the need for a joint linking the barrel with the output shaft.

The compact size offers high power-to-weight ratio and can be used in both open and closed loop applications. The SH7V is available in ISO and SAE mount, while the SH7VR is the gearbox plug version.

Brevini has also announced the SH11C fixed displacement motor, featuring a 40° bent axis angle.

With 12 displacements up to 180 cc/rev, the motors are suitable both for open and closed circuit application and can be used on heavy-duty applications for industrial applications on stationary machines and on mobile vehicles.

The motors utilise convex valve plates to provide high-performance units capable of up to 430 bar continuous and 480 bar peak pressure.

Brevini Australia Pty Ltd Contact info and more items like this at wf.net.au/R246

16 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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PNEUMATIC+HYDRAULIC

PRODUCTS

NEW White Papers

COMPRESSOR WITH INTEGRATED CONTROLLER

now available online!

Advanced pressure diagnostics provide valuable insight into your process Advanced pressure diagnostic technology provides a means for early detection of abnormal situations in a process environment and enables the user to proactively respond to changes in the process, troubleshoot and prevent future shutdowns. Find out how it can help prevent abnormal situations in your plant.

Global networks for M2M M2M has a relatively short history, having been around since 2000 when it became apparent that communication between machines carrying out similar functions would be a good idea.

It has since broadened into communication between dissimilar devices, examples being medicine and mining. This eBook explains more about this technology.

The Kaeser Sigma Control 2 (SC2) is equipped with its own

Power quality eBook With equipment and energy costs rising, itâ&#x20AC;&#x2122;s hard to stress enough the importance of power quality. Power quality issues can hamper production processes, damage costly equipment and lower productivity. This eBook features articles on power quality challenges, managing and reporting problems, improving efficiencies and reducing costs. Download now.

industrial PC as standard, including a web server, allowing direct communication with the compressor via intranet/internet. Passwordprotected compressor settings and operational data can be called up and adjusted on any PC with an internet browser without the need for software. Compressor operation and maintenance are therefore made even easier, as is regular monitoring of cost and energy efficiency.

The large operating panel has an LED backlit, 256 x 128 pixel, greyscale LCD screen on which plain text messages can be easily

A guide to EN Standards for gloves Hand injuries are the main contributor to overall injuries sustained by workers in Australia. It is therefore important that both employers and employees are well versed in standards for protective gloves. This white paper provides detailed insights on different risk categories and standards for protective gloves.

read across eight 30-character lines. Nine LED indicators signal additional operational parameters and conditions, and 13 membrane keys labelled with easy-to-understand icons ensure unmistakeable input of the various commands.

The operating panel communicates directly with the control system, the core of the Sigma Control 2. It comes with four interfaces for active and passive communication: IO-BUS for up to six I/O modules within the compressor; Sigma Frequency Control speed controllers, enabling the use of infinitely variable, frequency speed control for the compressor and for fans; an RJ45 ethernet interface (10/100 Mbps); and plug-in communication modules available for Profibus, Modbus, ProfiNet or DeviceNet. An SD card slot is available for data transfer as well as for software updates onto the SC2 using pre-loaded SD cards. Updates can be carried out quickly while all operational settings are retained. Integrated RFID functionality ensures secure login for users or Kaeser service engineers, and safeguards the system against unauthorised changes or operation.

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

18 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

Kaeser Compressors Australia Contact info and more items like this at wf.net.au/Q279

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NEW PRODUCTS

PLATE HEAT EXCHANGERS Teralba Industries has released a range of plate heat exchangers designed for pasteurising and general cooling and heating of beverages, food, dairy, brewery and viscous products.

With a compact footprint, units can be sized and configured for specific applications. The heat exchangers can be selected from models designed for flow rates as low as 200 L/h, increasing up to 1.2 million L/h.

Available with all stainless steel components, the plate heat exchangers are designed to provide hygienic and low-maintenance operation to food and beverage manufacturers.

The stainless steel reduces the need for epoxy coatings or spray paints used with traditional mild-steel frames.

The company claims the stainless steel construction provides several other advantages, including lower maintenance costs, aesthetics, elimination of painting and a sanitary finish with high-corrosive resistance. The units include plate materials, such as grade 316 stainless steel and titanium, to resist corrosion.

The product range includes: the FrontLine series, constructed of premium stainless steel; the BaseLine series, constructed of standard stainless steel; the TS6-M, which includes tall and short models; and AlfaNova welded plate heat exchangers.

The exchangers are suitable for use in production of soups, sauces, jams, starch heating, wine, fruit juices and similar food products.

Teralba Industries Contact info and more items like this at wf.net.au/Q498

PRESSURE TRANSDUCERS Setra Systems has introduced the Model 3100/3200 series, a family of compact, low-cost, high-pressure transducers, designed to support the rigorous performance demands of high-volume OEM applications, and particularly within space-constrained environments.

Available in standard (Model 3100) and heavy-duty (Model 3200) versions, the 3100/3200 series incorporates the use of thin-film strain gauge sensing technology in a Wheatstone bridge configuration.

The 3100/3200 series is available in standard duty ranges from 50 to 32,000 psi (4 to 2200 bar) with up to 3x overpressure protection. The Model 3200 heavy-duty version offers a thicker diaphragm and optional restrictor or snubber, making it operational in environments where extreme positive or negative pressure spikes may be of concern. Both versions offer 0.25% full-scale measurement accuracy, with long-term stability of better than ±0.1% FS per year, over an operating temperature range of -40 to +105°C. The series is available with the choice of mA, voltage or ratiometric output. Voltage output versions are available with dual temperature and pressure outputs for both models. Its small diameter, measuring less than 25 mm, allows for ease of installation within space-constrained environments. Units are reverse-wire protected. They are also UL listed, meet CE and EMC standards, and are fully RoHS compliant.

The series is suitable for larger volume, low-cost OEM applications, including medical devices and diagnostic equipment, hydraulic and pneumatic systems, HVAC/R compressors, variable speed pumps, refrigeration systems, industrial pumps and general industrial pressure monitoring applications.

COLOUR TOUCH SCREENS PLC Hardware Pty Ltd supplies a range of industrial panel mount colour touch screens by Norco. The range includes solid 6 mm aluminium front bezels with strengthened glass and IP65 rugged construction.

The 17″ widescreen model features a 1400 x 900 resolution, WXGA, TFT LCD plus on-screen display with control keys to customise the set-up. The analog resistive touchscreen units have DVI and VGA input and also an audio jack input for internal stereo speakers.

The slimline units meet VESA mounting standards with external dimensions of 440 W x 302.5 H x 54.3 D for the 17″ widescreen unit. The user can utilise the wide range AC power adapters or supply the screens independently via a 24 VDC supply.

There is a wide range of sizes and options including serial and USB touch screen drivers. The screens provide a luminance of 250 cd/m2 and a viewing angle of 160°, both

Pryde Measurement Pty Ltd

horizontal and vertical.

Contact info and more items like this at wf.net.au/R101

PLC Hardware Contact info and more items like this at wf.net.au/Q736

20 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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NEW PRODUCTS

MULTIPARAMETER CONTROLLER The mxControl 8620 multiparameter controller is designed to automate the control of process variables within a water treatment system and reduce controller and instrument costs by as much as half. The 8620 integrates all control, monitoring and display features as well as data and event logging functions into one compact unit. The 8620 is suitable for primary water treatment processes or ancillary processes in manufacturing, mining and general industry.

The controller is easily configured to display, transmit and record flow, pressure, pH/ORP, conductivity, turbidity, O2, O3, Cl2, level and temperature. It accepts standard 4-20 mA inputs from the field instruments and provides high level computations to optimise the water treatment process. The compact unit is designed for use in water treatment, cooling towers, RO applications and boiler systems.

The mxControl system is capable of processing up to four analog, two RTD and eight digital inputs as well as five relay,

CODED SAFETY SWITCHES Pilz has expanded its range of PSENcode coded safety switches with a safety switch that provides safe monitoring of up to three positions in accordance with up to PL e of EN ISO 13489-1 and SIL CL 3 of EN/IEC 62061. The coded safety switch also undertakes safe position detection. As a result, only one safe sensor is required for position monitoring. No additional sensors are needed and the number of safe inputs on the evaluation device are reduced.

Diagnostics are quick and user friendly via LED display, for both the compact and the large design. With the connection type (M12 connector, 5-pin), the PSENcode is suitable for any system environment.

With a non-contact action principle, PSENcode units have a long product service life, providing increased investment protection. PSENcode switches are flexible to install, as the sensors and actuators support all actuation and approach directions.

When combined with the PNOZmulti Mini configurable safety relays, the PNOZmulti configurable control systems and the PSS programmable control systems, the result is a safe, complete solution comprising control and sensor technology.

four digital transistor and four optional analog outputs - totalling 23 I/O - simultaneously (model dependent).

Parameters are loaded by SD card or from a standard PC, via the USB interface. An optional ethernet interface can be used to configure and parameterise the controller remotely or be used to send email or SMS alerts in the event of an alarm situation.

All important variables and parameters may be raised via five soft-touch keys, with the operator able to grant varied access via the built-in security system.

Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/N811

Pilz Australia Industrial Automation LP Contact info and more items like this at wf.net.au/R210

SIL 3 VALVE ACTUATOR The Limitorque MXa valve actuator from Flowserve has a SIL 3 rating and is designed to provide customers with reliable actuation in critical environments without compromising their safety instrumented systems. The SIL 3 capable rating was obtained from Exida Certification Services after passing rigorous failure mode effects design analysis (FMEDA) and total time in service tests. It carries the safety rating in a one out of two (1oo2) configuration, which requires two actuators and valves to be installed into a SIL 3 rated environment.

Limitorque MXa has multiple features that make it advantageous for critical environments requiring SIL 3 certification, including LimiGard technology that automatically monitors the health of each coded signal and is designed to ensure that no component failure can cause the actuator to move unexpectedly.

Also a part of the LimiGard technology is an absolute encoder designed with a built-in self-test (BIST) capability. The BIST feature confirms the sound operation of the encoder, ensuring the actuator is operating safely.

The MXa SIL 3 capable rating is a standard configuration that includes S1 and S2 contacts as well as the monitor relay. This ensures that the user does not need to utilise external SIL-rated contacts.

Acrodyne Pty Ltd Contact info and more items like this at wf.net.au/R078

22 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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REDEFINING THE SCADA ARCHITECTURE DISTRIBUTED ARCHITECTURE HELPS UTILITIES SUPPORT A MORE INTELLIGENT GRID

SCADA systems have been in use for many years at electric utilities. The basic architecture of the SCADA system has remained constant since the first systems were installed over 30 years ago, which were based on the most current information technology available. But as centralised information technology has advanced towards the use of decentralised PCs with servers, the utility’s SCADA architecture has not kept pace.

T

he challenge with the traditional SCADA architecture is the higher costs associated with new substations and limited flexibility when functional requirements, equipment additions and physical layout changes are required. As with most changes in the electric utility world, a valid business and operational case must be made to justify changes to designs and investments.

telephone, two-way radio, microwave and fibre. At the substation end of the communications connection is an RTU, which may be the data concentrator or may have an external concentrator. It is connected to the utility relays that control substation equipment such as breakers; the connections within the substation are generally done with a local area network (a fibre ring or copper cables).

Current utility architecture

The technology opportunity

Today, the most common type of IT architecture is based on a central server located at the utility’s control centre that acts as the central core of the SCADA solution. Access to the real-time information, status and alarms of the utility’s substations is visible to control centre operators through local workstations (desktop PCs). However, non-real-time information, which is useful for analysing sequence of events (SOE), alarms and maintenance, is left in the relays (intelligent electronic devices - IEDs).

The real-time information is brought into a utility’s control centre through a variety of communications methods, including

Looking back at the evolution of computing architecture, in the 1980s most computing was done on mainframe computers.

The use of ‘dumb’ terminals was eventually replaced with PCs with the ability to do some computing; and today, we use PCs connected via wired and wireless connections to servers. Data can be transferred quickly with computing being done either at the server with a thin client PC or on the PC (a thick client).

The traditional SCADA utility architecture is similar to that of the mainframe computer, where all computations and memory exists in a central repository. In an age of cyber security attacks,

24 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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Š iStockphoto.com/David Sucsy

SCADA

the weakness of this type of architecture becomes obvious; having all the data stored in one location may enable easier protection of data and systems, but also significantly increases the devastation that can be caused by a successful attack. If a virus or other cyberattack knocks out the main SCADA system, the utility is left with no visibility into its operations.

The current utility SCADA architecture is now ripe for the same type of evolution that took place in computing - towards a distributed architecture. Utilities that embrace advancements in technology and act on this opportunity can realise the benefits that come through diversifying the computing and data while preparing the utility for a more intelligent grid.

Increasing visibility with local HMI With the traditional architecture, there is typically no way to access the SCADA system at the substation. Using a laptop, data from modern electronic relays (IEDs) can be accessed using a port on the relay or through ports on the RTU. As a result, engineers that need access to alarm data, breaker operation his-

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tory and SOEs (for example, the timing of breaker and backup breaker operations to verify timing settings) need to travel to the substation or utilise the main SCADA system. For security reasons, utilities may limit SCADA access, which then increases the complexity of reviewing data for standard engineering work.

As a result, some utilities have started to add local HMIs within the fence of larger substations to provide access to the data needed by engineers. The local HMI is usually constructed from a single board computer with no moving parts, including flash-only memory, HMI/SCADA software and a historian database; this is an interim step to moving to a fully distributed architecture.

While these systems can be blocked from operating breakers, a web interface can provide engineers with access to the HMI remotely. The HMI software is generally the same or similar to the software installed at the control centre, and an entirely different communications method from the primary SCADA can be used for these installations, including secure internet access.

A local HMI connects to the LAN within the substation and constantly retrieves and stores data from the IEDs. In the traditional architecture, only about 30% of this data is backhauled to the control centre through the RTU and consists of data needed for real-time operations. The other 70% of data available, which is not needed for real-time operations, is not captured - leaving behind a mine of historical information that can provide critical intelligence to engineers and maintenance planners.

Having a local HMI allows all of this data (both real-time and non-real-time) to be collected into a single repository with a common clock. The information provides the foundation for root-cause analysis, trending and predictive diagnostics, providing deep visibility and valuable insight into areas such as breaker operations and maintenance requirements - enabling greater reliability and efficiency.

Benefits of distributed architecture The use of a local HMI enables a distributed architecture SCADA system, which presents an entirely new way to configure the utility substation with less complexity and more accessibility for engineers and technicians. It consists of local HMIs with full SCADA control and a central control room that provides visibility, command and control, and data retrieval by utilising the HMIs - providing the infrastructure for a smarter grid that delivers improved operational and financial results.

The new architecture allows utilities to expand functional operations by preparing for smart grid functionalities without major reprogramming of a large SCADA system. From a physical layout perspective, this architecture allows for greater physical flexibility in substation expansions and eliminates the need for the RTU/data concentrator.

At new substations, control houses are often built to house the relays that control the breakers, allowing technicians to

SEPTEMBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

SCADA

Figure 1: Traditional SCADA architecture.

Figure 2: Substation HMI architecture with local HMI.

THE CURRENT UTILITY SCADA ARCHITECTURE IS NOW RIPE FOR THE SAME TYPE OF EVOLUTION THAT TOOK PLACE IN COMPUTING - TOWARDS A DISTRIBUTED ARCHITECTURE. UTILITIES THAT EMBRACE ADVANCEMENTS IN TECHNOLOGY AND ACT ON THIS OPPORTUNITY CAN REALISE THE BENEFITS THAT COME THROUGH DIVERSIFYING THE COMPUTING AND DATA WHILE PREPARING THE UTILITY FOR A MORE INTELLIGENT GRID.

work on the relays in all types of weather - an expense that has become accepted but should now be questioned. Using a distributed architecture, a control building is no longer necessary because the local SCADA acts as a gateway, allowing for reprogramming of all points accessible to the local SCADA. Therefore, the relays can go back into the breaker cabinets and be interrogated and programmed from the engineer’s desk - thus eliminating travel time to the substation. Without the need for the house, the panels and racks in the house can be eliminated, as well as the time and costs associated with pulling and landing multiple sets of copper relay cables.

And finally, standardisation plays a key role. The expensive custom SCADA systems with their high annual maintenance fees can be eliminated as a version of the SCADA software is installed on common Windows servers in the control room. This version of the software views the thick clients in the substation through traditional communications channels or newer ones as the utility creates them.

Improved insight and reliability The use of the local SCADA as a thick client allows for simpler creation of the screens and point connections using the IEC61850 communications protocol, which helps decrease install time, and the screens can be easily replicated in the control room. The local SCADA will have high-speed storage of all events available to the relays, supported by an appropriate database.

The high-speed data historian can capture all the points and replicate the data into the control room at any time for analysis, or the analysis can be done via the web on the thick client at the substation from an engineer’s desk. The local SCADA can also be used to review the data from phasor monitoring units (PMUs) to

26 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

detect anomalies on the transmission grid and transmit the data to phasor data concentrators (PDCs). It can utilise a common clock for all relay operations, thus properly ordering the SOEs of breakers without trying to account for time stamp errors.

Furthermore, the local SCADA puts computing power out into the field where the next two areas of evolution to the grid will occur: distributed generation and micro-grids. With the computing power put closer to the distribution assets, the system can utilise meter data without extensive backhaul and processing delays. It can automatically balance the substation’s loads and resources, and island the substation or sections of the distribution system automatically for continuous operations. For operations involving multiple substations, the control room SCADA system will oversee the coordination of activities.

Impacts on substation design and construction The changes espoused here have a profound impact on the physical layout of the substation. Traditional substation layouts include a building to house the battery bank, IED relays, lowvoltage breakers, RTU and communications equipment. These block buildings needed to be centrally located within the substation due to signal attenuation and voltage drops; the extensive cabling required for bringing each point from the breaker to the relays, the low-voltage AC power, and DC power can now be reduced to the LAN cables and the AC and DC power.

Reduced cabling eliminates the need for the cable trench system that occupies large areas and limits material locations, truck accessibility and expansion of the substation. Without the building and trench system, the substation also becomes less costly to construct and easier to modify for expansions and new equipment installations.

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SCADA

Figure 3: Distributed SCADA architecture.

Figure 4: Substation physical layout expansion conflicts.

The few remaining items from the house, such as batteries installed in large cabinets with local air conditioning (if required), can be relocated should a substation redesign be initiated. The HMI and other communications equipment can also be located in free-standing cabinets, enabling a much smaller footprint.

Migration strategy For utilities with an existing large, centrally controlled SCADA system, a planned migration strategy is required to evolve towards a distributed architecture system.

• The first phase will be to install the local HMI on single board computers with flash memory in each substation. The system can be completely configured but used only as the local HMI until these single board computers are installed in every substation; these can be accessed via existing large-scale EMS systems.

• The second phase will be to install redundant (or quad) servers in the control room operating in parallel with the existing central SCADA system.

• The third phase will be to complete the communications links to the HMIs. These can be done through any of the various secure communications methods currently available such as fibre, radio, microwave or even internet, but larger bandwidth systems are preferred.

• Finally, the HMIs will be converted to local SCADA with the functionality tested before going live. The old systems can then be used as backup or removed to eliminate any unauthorised access into the substations.

Servers in the control centre should be isolated from the enterprise data systems by unidirectional firewalls that allow data out of the control centre into enterprise systems but not

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data from the enterprise system into the control centre, as this will help protect against hacking and unauthorised use.

Conclusion While substation SCADA architecture has not changed much since utilities first employed SCADA in the 1980s, computing technologies and architectures have evolved, making it possible for utilities to rethink how they design their substations and operate their electric transmission and distribution systems. By embracing a new distributed architecture with local HMI, utilities can take a significant leap forward towards a smarter grid.

The advantages of leveraging a distributed architecture are twofold: it increases the functionality of the SCADA system to allow for comprehensive data access by engineers and it allows for a much simpler and more flexible substation layout. Adding to the ease for migration, the replacement of legacy ‘mainframe’ SCADA systems no longer requires extensive consulting assignments and customised programing, and standardisation based on IEC61850 makes SCADA system configuration faster and more robust.

The changes may seem radical but utilities that can leverage the technologies available today can reap ongoing benefits, including reduced costs, greater flexibility and ease of use. The business case to drive this new distributed architecture off the drawing board and onto the grid is more compelling now than ever as utilities focus on improved operational performance and financial sustainability.

GE Intelligent Platforms Asia Pacific Pte Ltd Contact info and more items like this at wf.net.au/R117

SEPTEMBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

NEW PRODUCTS

WIRELESSHART ADAPTER Moore Industries and MACTek Corporation have worked together to

ETHERNET/IP COMMUNICATION ADAPTER MODULE The FLEX I/O Dual Port EtherNet/IP Communication Adapter Module (1794-AENTR) includes two EtherNet/IP ports configured as embedded switches that support not only the conventional star and tree topologies but also the daisy chain and Device Level Ring (DLR) topologies. The DLR

jointly supply the Bullet WirelessHART adapter. Engineered by MACTek Corporation, the Bullet is part of a solution for sending smart HART and analog process signals over WirelessHART networks.

The Bullet can send process signals from just one or up to eight multidropped smart HART transmitters on a WirelessHART link. In addition, it can work with Moore Industriesâ&#x20AC;&#x2122; TCS Temperature Concentrator System to send up to 16 temperature measurements across a WirelessHART network. The multidrop capability of the Bullet can reduce costs along with simplifying the process of connecting HART devices to a wireless network.

The full line of general-purpose (GP), intrinsically safe (IS) and explosion-proof (XP) Bullet products allow users to get the most out of all smart HART devices from Moore Industries as well as devices and valves or HART I/O made by other manufacturers.

Supporting both WirelessHART mesh and star network configurations, the Bullet can be connected directly to a HART device or at any junction box along the HART 4-20 mA

topology provides a level of communication redundancy that enhances product availability. DLR also reduces and simplifies network wiring.

It can connect up to eight FLEX I/O modules per adapter module. The extreme environment (1794-AENTRXT) version of the communication adapter module operates in a broader temperature spectrum of -20 to 70°C and provides a solution for extreme environment applications.

FLEX I/O is claimed to be a cost-effective, flexible, modular I/O system for distributed applications and offers the functions of larger rack-based I/O, without the space

loop. It sends process signals including first, second, third and fourth measurement variables, custom diagnostic and alarm data and custom commands. It also accepts analog signals such as 4-20 mA, making it a suitable choice for adapting legacy analog instruments to WirelessHART networks.

The rugged XP-rated Bullet can be powered either by an external DC power supply or by scavenging from existing loop-power.

Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/Q483

requirement. Users can independently select the I/O type, termination and network.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/Q380

28 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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CLICK Series Programmable Logic Controllers (PLCs) The Almost Free PLC ... Only $99.00

Download the FREE CLICK PLC Programming Software www.automationdirect.com.au

CLICK™ Series Programmable Logic Controllers (PLCs) Why buy a smart relay when you can have a real PLC for less?

The almost free micro PLC starting at only $99.00

The CLICK PLC offers a scalable solution. The stand-alone CPUs can compete on size, price and ease of use with hardware designed for microprojects, even programmable relays. But they’re also expandable and have features you'd expect in a practical PLC, a great fit for small projects... and nice to have when feature creep turns your micro project into a small project! Try the full-feature FREE Programming Software.

Easy Installation •The CLICK PLC control system does not require a mounting base, which saves on space.

•The CLICK CPU and I/O modules are connected together via an expansion port on the sides of the modules.

Expandable I/O •A powered CLICK CPU module can be used as a complete standalone PLC control system with eight input points and six output points built-in, •Or, the PLC controller can be expanded with the addition of up to eight I/O modules.

•A variety of I/O modules are available for flexible and optimal PLC system configuration. The I/O numbering system is decimal.

Built-in Communications •CLICK Basic CPUs have two built-in RS-232 communications ports that can be configured for either MODBUS RTU or ASCII networks.

•CLICK Standard and Analog CPUs have an additional built-in RS-485 communications port Analog Input/ Analog Output •Analog CPU modules have built-in analog I/O (2-channel analog inputs and 2-channel analog outputs).

•Each channel can be separately set for voltage (0 to 5 VDC) or current (4 to 20 mA).

Calendar / Clock & Battery Backup •Standard and Analog CPU modules include the real time clock and battery backup for the internal SRAM. •Battery allows data to be stored for 5 years.

FREE PLC Programming Software •The CLICK PLC supports a very simple, but useful set of 21 easy to use instructions.

•The 21 instructions cover most applications that are suitable for this class of programmable logic controller.

•Download FREE CLICK PLC Programming Software Now! Australia Wide: 1-800-6330405 New Zealand: 0-800-6330405 Asia Pacific: 61-7-55874222 TECHNOLOGY THAT MAKES YOUR JOB EASIER E: sales@automationdirect.com.au Fax: 61-7-55252053

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NEW PRODUCTS

MULTITOUCH PANEL PC The Avalue OPC-15W6 is a multitouch panel PC designed to meet expectations for the current popular touch and gesture UI applications.

PREDICTIVE DIAGNOSTIC SOFTWARE GE Intelligent Platforms has announced Proficy SmartSignal Shield 4.0 software for the oil and gas and power industries.

It is designed to provide early warning of impending problems, diagnostic guidance and prioritised actionable intelligence.

With the software, users can move from reactive to proactive maintenance by working on the equipment that needs to be fixed, and on the most critical problems first.

The software was developed based on shared blind data from GE customers.

From experience based on millions of machine hours and tens of thousands of failures from over 12,000 rotating and non-rotating assets, GE was able to identify fault patterns, in the context of operating behaviour and incorporate them into software.

Features include an open-frame 15.6″ wide screen, powered by the second generation Intel Core i7 and Corei3 processors, and a projected capacitive (PCAP) touch screen.

The OPC-15W6 allows system integrators and software developers to design more intuitive touch and gesture applications. The system is designed to be completely fanless and is a suitable solution for self-service kiosks, point of information (POI) and HMI applications. The capability of OPC-15W6, together with touch and gesture UI design applications, can help to meet newer expectations in human-machine interaction.

Backplane Systems Technology Pty Ltd Contact info and more items like this at wf.net.au/R116

The software’s diagnostic algorithms combine observations on multiple individual sensors to pinpoint failure effects. Beyond vibration and thermal analyses, the solution models all data on all critical rotating and non-rotating equipment. The solution monitors equipment automatically and continuously, enabling users to take necessary mitigation and to organise maintenance projects.

The newest release includes a suite of applications that enable quick design and implementation. The software allows for clear access to diagnostics and rules, so users can fully understand and adjust the software based on their own expertise. This means a more comprehensive embodiment of users’ subjectmatter expertise on equipment operation and management can be deployed so the intelligence of both GE and users is automated and constantly standing guard to shield critical assets.

Metromatics Pty Ltd Contact info and more items like this at wf.net.au/N816

30 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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NEW

PLANETARY GEAR UNITS

PRODUCTS

SEW-Eurodrive Australia has added two sizes to its P-Series of standard gear products: P072 and P082. With these two additions, the P-Series now covers rated

ONLINE TURBIDITY ANALYSER

torques up to 500 kNm. The planetary gear

The Swiss-made Sigrist AquaScat turbidity analyser

units can be used in all applications where

uses a free-falling sample design in which the water

low speeds and high torques are required.

sample is never in contact with the cell. The cell

The P-Series of industrial planetary gear

measures turbidity through the entire sample by the

units is now available in 11 sizes and cov-

90° scattered light principle (ISO 7027). This contact-

ers the torque range from 24 to 500 kNm.

less design eliminates fouling and the necessity for

The gear units are designed so that the

regular cleaning.

gearmotor is directly mounted in front of the

Dependability of readings is enhanced by stable

planetary gear unit. This eliminates the need

Zerodur optics calibration which is initiated automatically

for couplings, intermediate flanges and

by the AquaScat WTMA or manually by the AquaScat

adapter flanges, saving space and cost.

WTM. Both units have a fine resolution of 0.001 NTU

Several different designs enable the gear units to be optimised for the user’s appli-

for low-turbidity monitoring.

cation. SEW’s gearmotors offer a wide variety at the input. This results in precise gear

For high-turbidity applications, the AquaScat HT

unit ratio grades. It is possible to combine the designs with the planetary gear unit in

will offer the same non-contact reliability in difficult

helical or bevel-helical gear versions. The P-Series is designed to be particularly short

applications. The AquaScat P is for applications

and compact. The gears feature high torsional rigidity and can transmit high torques.

under pressure. All AquaScat models have a range

The industrial planetary gearmotors can be used in all applications where heavy

of 0-4000 NTU.

objects are moved at low speed including: plate conveyor drives in conveyor systems,

The operator interface is a touch-screen colour

silo discharge systems for mixers and agitators, remote drives for wood pulp presses

graphic display. The product features two 4-20 mA and

in the pulp and paper industry, and bucket wheel drives for mining.

a choice of digital outputs, and a data-logger which

SEW-Eurodrive Pty Ltd

stores data onto its internal microSD card.

Contact info and more items like this at wf.net.au/Q830

B-R Controls Pty Ltd Contact info and more items like this at wf.net.au/R019

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SEPTEMBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

SEW-Eurodrive conveyor drives keep things moving at Swire

An upgraded conveyor system has helped Australia’s largest cold-chain logistics service provider stay on top of its game - at low cost.

Handling more than 30,000 boxes each day, Swire Cold Storage’s Cannon Hill site relies heavily on its conveyor system. As production levels rose over the years, however, it became apparent that Swire’s ageing conveyor system wasn’t handling the increased volume.

“Because of the high volume of boxes coming down the main conveyor line, the chain drive pushers just couldn’t cope at peak times, with the boxes getting caught up and forcing us to stop the whole conveyor line,” explains Colin Carter, Swire’s Queensland Engineering Manager.

Any downtime in the operation directly impacts Swire’s customers, something Swire was keen to minimise. After trying a number of approaches to address the problem, Swire approached SEW-Eurodrive.

“In the end, using SEW-Eurodrive’s smart products and the company’s in-depth knowledge of conveyor systems, we managed to fix the problem for far less money than we initially thought,” said Carter. “In fact, it was a very low-cost project for such a big improvement to our production efficiency.”

SEW-Eurodrive Applications Engineer Shahry Zand considered solutions for Swire’s pusher problem. He thought a servo drive with a high-resolution encoder would be ideal for the application, but it wasn’t going to be cheap: over $100,000 for the total solution. But Zand found a solution for Swire that was efficient and affordable. The original motor was replaced with an SEW-Eurodrive high-efficiency motor, and an

32 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

MQD DeviceNet module with internal positioning and sequence control (IPOS) capabilities replaced the original module.

To achieve a pushing cycle of less than 0.5 s, a speed profile was programmed in IPOS based on the pusher position. The aim of the set-up was to prevent the boxes being damaged by being hit at high speed while being able to stop the pusher at the home prox within the required accuracy.

“Thanks to the new built-in encoder, the pusher hasn’t missed the Home Prox even once and it’s pushing the boxes quicker and smoother than ever before,” said Zand.

With this solution, SEW-Eurodrive was able to fix the problem for less than $2200. Even better, the conveyor took just one day to install and was completed over a weekend, which meant no disruption to Swire’s production at all.

Carter is very impressed with the improvements and SEW-Eurodrive.

“Their engineering skills and professionalism are first class. Since putting in the new drive our downtime has decreased considerably. In fact, I’ve just ordered three more drives from SEW-Eurodrive.

“We have over 150 of their drives on site and over 200 SEW-Eurodrive motors and gearboxes,” said Carter. “Basically, you get what you pay for. There are probably cheaper drives on the market but they don’t go the distance. SEW-Eurodrive products are very flexible and reliable.”

SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/Q495

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NEW PRODUCTS

ARC WELDING ROBOT The IRB 1520ID arc welding robot is designed for use in metal fabrication, and with its integrated process dressing technology, all power cables and necessary gas and pressurised air hoses are integrated into the arm of the robot providing a shielded dressing or covering. This protection provides greater safety for operators plus more simplified robotic programming with more predictable welding results without estimating for swinging cables.

The risk of sharp metals damaging cables - which can cause serious hazard for operators - is reduced. With the cabling tucked away, the life span of the cabling and the robot itself is also extended.

Besides reducing safety risks for welders, the integrated dressing design increases accuracy and allows for more flexible movements. More uninhibited movement is needed, for example, for single-motion welds around cylindrical objects or hard-to-reach weld seams. The IRB 1520ID robot has been designed with a slim upper arm design, allowing easy access to narrow spaces. With a reach of 1.5 m and payload capacity of 4 kg, the robot can be mounted on the floor or inverted for flexibility, offering shorter cycle times and a wide range of production possibilities.

ABBâ&#x20AC;&#x2122;s IRB 1520ID interfaces with the FlexPendant HMI, which can be used by operators with minimum training. The power source interface is also fully integrated so users have full control over voltage, current, speed, gas flow and other welding parameters from the same interface as the robot.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/Q842

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SEPTEMBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

NEW

SERVOMOTORS

PRODUCTS

The Pilz PMCtendo SZ servomotors are now available in different cooling types.

Due to their short overall length and low weight, all the servo motors have a

CLAMP METERS

high power density. PMCtendo SZs are

The Fluke 320 Series true-RMS clamp meters comprise

characterised by quiet operation and

a range of tools engineered to produce noise-free and

high process quality due to low cogging

reliable measurements in tough environments.

torques. As a result, the servomotors

Designed to be long lasting and easy to use, the

are suitable for use in applications with

Fluke 323, 324 and 325 clamp meters are suitable for

onboard axes and in cramped conditions.

rugged, all-purpose use in residential, commercial,

They are suitable for all drive solutions

HVAC/R and light industrial electrical applications.

in a variety of industries.

The series clamp meters feature a slim, ergonomic

PMCtendo SZs have optimised heat

design for comfortable all-day use, a large, easy-to-read

dissipation, ensuring high performance.

display and CAT III 600 V/CAT IV 300 V safety ratings.

High-resolution absolute value encoder systems provide

They can be used to measure true-RMS AC voltage and

high performance and absolute positioning. With their high

current for accurate measurement of non-linear signals,

efficiency factor, these servomotors exceed the requirements

as well as DC current, frequency and resistance up to

of the international efficiency class IEÂ 4.

40 kilohms for motor testing.

All motors are available with different cooling types - as

The 324 and 325 models offer a backlit display for

water coolers, with external fans or with natural convection.

easy viewing in any setting, contact temperature read-

The models with external fans offer considerably higher

ings from 10 to 400°C and capacitance measurements

performance, as do the water-cooled motors, which achieve

from 100 to 1000 microfarads. The 325 model also of-

around 35% higher performance than the basic convection

fers DC current measurements up to 400 A, frequency

model. The latter can also be used with high ambient tem-

measurements from 5 to 500 Hz and a min/max function.

peratures, without any loss in performance.

Fluke Australia Pty Ltd

Pilz Australia Industrial Automation LP

Contact info and more items like this at wf.net.au/Q738

Contact info and more items like this at wf.net.au/R211

Ventilex manufactures the finest and energy efficient Coolers Belt Dryers Flash Dryers Fluid Bed Dryers Air Dehumidifiers Steam Sterilization Air Pollution Control Continuous Steam Pasteurisation For the Food Manufacturing Industry

Brolton Group Pty Ltd

69 Princes St, Riverstone, NSW, 2765, Australia Sydney Ph: +61 2 98381311 Perth Ph: +61 8 6263 4426 Fax: +61 2 9838 3113 E: sales@brolton.com.au www.brolton.com.au www.sanddryer.com.au

34 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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ROTARY SINGLE-AXIS INCLINOMETER Turck has introduced a rotary single-axis inclinometer, expanding its dual-axis CANopen inclinometer offering for angular tilt detection.

With a monitoring range of 360째, the single-axis inclinometer provides extended application flexibility, allowing operators to easily monitor mechanical arms, such as tensioners or moving components. Its CANopen communications also makes it suitable for mobile equipment, such as monitoring and reporting position of outriggers, booms or other vertically rotating parts.

The single-axis inclinometer measures angular tilt in reference to gravity. At the heart of the inclinometer are MEMS (microelectromechanical system) devices that incorporate capacitive elements utilising two parallel plate electrodes, one stationary and one attached to a spring-mass system. Movement causes acceleration that produces deflection in the non-stationary electrodes. This results in a measurable change in the capacitance between the two plates that is proportional to the angle of deflection. All measured values and parameters are accessible via the object directory. The micro board design in the MEMS technology allows for a compact, precise inclinometer in a robust, industrialised package.

The Turck single-axis inclinometers offer a rugged, IP68-rated housing and reliable operation in temperatures ranging from -40 to +70째C. Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/Q418

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SEPTEMBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

NEW PRODUCTS

PHOTOELECTRIC SENSOR The ifm efector OG-Cube photoelectric sensor has a robust metal housing with a 2-wire output stage. The minimum leakage current of 1.7 mA means the photoelectric sensor can be used in normal AC power mains at 20 to 250 VAC. The sensor is suitable for harsh industrial environments. The technology in a compact and robust housing provides good flexibility when used in adverse applications where space is restricted.

Due to a minimum drift when light and dark objects are

MANUAL DUMP SYSTEM WITH COMPACTOR The manual dump system from Flexicon collects dust generated during manual tipping, compacts empty bags and conveys bulk material downstream. The dust-free system comprises a receiving hopper, dust collector, bag compactor and flexible screw conveyor.

A bag infeed chute through the sidewall of the hopper hood allows the operator to pass empty bags directly into the bag compactor, causing dust generated from both tipping and compaction to be drawn onto the systemâ&#x20AC;&#x2122;s two cartridge filters. An automatic reversepulse filter cleaning system releases short blasts of compressed air inside the filters at timed intervals causing dust build-up on the outer surfaces to fall into the hopper, conserving usable product.

Filters are readily accessed by removing the interior baffle, and replaced rapidly using quick-disconnect fittings. detected, the sensor is claimed to achieve long ranges which

The compactor employs a large pneumatic air cylinder to com-

remain constant even with coloured backgrounds. Additionally,

press bags into a removable bin that accommodates 50 to 80

the operation of the sensor is colour independent for greyscale

bags. The main door, and a flapper door within the bag infeed

and black values. Additional features include good repeatability

chute, are equipped with safety interlocks that prevent operation

and fixed ranges for a quick set-up.

of the compactor unless both doors are closed.

The OG-Cube can be supplied as through-beam sensor, retro-

The hopper discharges into an enclosed, flexible screw conveyor

reflective sensor and diffuse reflection sensor with background

designed to handle a broad variety of materials including free- and

suppression. A range of mounting accessories is available for

non-free-flowing bulk materials from large pellets to submicron

universal mounting.

powders, including products that pack, cake, seize, smear, fluidise,

ifm efector pty ltd

break apart or separate, with no separation of blended products.

Contact info and more items like this at wf.net.au/Q831

Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/Q737

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AS I SEE IT ACCELERATING INNOVATION WITH SMALLER TEAMS

A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson

I

ntelligence is being added to more systems every day. Smart power metering, home automation and in-home medical devices are a few examples that will be ubiquitous in just a few years. Not only are there more embedded systems around us, they are also becoming more complex. The same trend in the consumer space can be seen in industry as well, as industry extends its capabilities by leveraging emerging technologies. Electronic systems and machines are adding control and monitoring systems that improve performance, quality and differentiation. As enabling technologies become available, our advanced manufacturing, process monitoring and control capabilities continue to expand. An ever-increasing number of design starts and escalating complexities are forcing embedded system design teams to be more efficient and are influencing the technology they choose to use. To address these market needs and help teams get to market faster, technology providers are developing components, modules or even complete embedded platforms with higher levels of integration and increased functionality. Ultimately, they are working towards a complete platform for embedded design containing communications, processing, system I/O and integrated system design software.

In the upcoming decade, software tools will play a more critical role in system design and development. In the past, many embedded designs were dictated by embedded hardware capabilities and mapping them to the system requirements. Due to the reduction in power, cost and size of embedded hardware over the last decade, hardware will no longer limit or dictate many embedded design choices productivity will. Productivity will be driven by tightly integrated software design tools that can use off-the-shelf hardware capabilities with an environment intuitive enough to be used by nearly all engineers and scientists, not only those trained in embedded software, firmware development or hardware description languages.

With the nature of the economic situation as it is today, businesses cannot just spend their way into innovation. Agile competitors are emerging around the world and are proving that innovation can happen just as fast, if

wnipt@westwick-farrow.com.au

not faster, in smaller design teams. They are delivering disruptive innovations to market in shorter time periods and with equivalent, and in some cases better, quality than their traditional competitors. This is happening in established economies and equally, if not more impressively, in emerging economies as well.

Looking at technology platforms and tools available to businesses today, there are two predominant competing design approaches.

One is the traditional way of thinking, which means for a business to deliver innovation, it has to vertically integrate the hardware and software stack itself and ‘own’ the design of all these components to deliver the quality and experience customers expect. This approach normally requires a larger design team and seems to fit better in industries where product volumes are astronomical or the design team is iterating on an existing custom design, like the consumer electronics market. The alternative methodology is the emerging approach of using off-the-shelf, system-level tools with a standard ecosystem of technology that can help accelerate the process of innovation without compromising the ability to differentiate. This approach has proved to be a better fit for areas of aggressive innovation, such as renewable energy, advanced manufacturing and robotics, as it uses standard off-the-shelf hardware components and prebuilt software tools that are friendlier and more tolerant to quick changes.

Matej Krajnc, Director, National Instruments Oceania, has over 25 years of engineering industry experience.

He is an internationally known speaker, trend analyst and applied engineering consultant. His expertise covers various fields, including automated test, control and design for the military, mining and automotive industries. Krajnc’s specialisations include process engineering, computer-based modelling, system integration and chemical engineering.

38 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2012

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