What's New in Process Technology October 2013

1013

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY OCTOBER 2013

CONTENTS

Telemecanique Sensors is a world-class global brand offering a comprehensive range of products with over 25,000 types of sensors - including limit switches, pressure sensors, proximity sensors, encoders and safety sensors. In ad-

4

Total cost of ownership

dition, Telemecanique provides state-of-the-art

A study of automation systems

RFID systems that are compatible with many PLC manufacturers. Manufacturing sensors and

8

New products

factory automation products for more than 90 years, Telemecanique Sensors is well known for

10

Hot products online

20

A holistic approach to conveyor belt monitoring

32

The six guidelines you need to specify a bulk bag filler

increasing R&D investment, developing new

40

RS485 data acquisition

establishing global adaptation centres to en-

A new chapter

50

As I see it

customer needs.

Choosing cogeneration for energy efficiency in food and beverage

allowing customers to focus on what is important,

its high-quality products and superior performance, providing all the right agency approvals.

Telemecanique Sensors understands the importance of staying competitive in today’s manufacturing environment. That is why it is

and innovative products that have a positive impact on production, while at the same time able a fast response and quick delivery of customised sensor products designed to meet Telemecanique’s aim is to simplify installation, improving their plant and machine performance.

A dedicated team of sensor application specialists works with customers to recommend the right solution, the first time. The Telemecanique team becomes an extension of your team, ready to share its expertise. Telemecanique provides logistics designed to meet the specific needs of its customers, with a worldwide supply chain and a network of local distribution. Its commitment is to ensure it is a reliable supplier and partner to your business.

Connect with the experts!

Schneider Electric (Aust) Pty Ltd www.schneider-electric.com/au

NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.

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TOTAL COST OF OWNERSHIP A STUDY OF AUTOMATION SYSTEMS Toby Kilroy, Senior Engineer, Omron Electronics Australia

It has often been said that we live in an age of solutions. Today, many vendors offer competing platforms for automation which accomplish much the same task, namely the automation of plant floor equipment and machinery. However, it is rare for manufacturing automation system users to properly investigate the total cost of ownership (TCO) for the range of automation platforms on offer.

4 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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T

he true cost of control systems is not just the initial purchase cost, but the sum of costs over the life of the system. This includes the three major phases of the system life cycle: • Purchase and commissioning • Operation • Decommissioning However, it is the initial purchase cost which is often fixated on, and decisions made only on this up-front price. But the true cost throughout the life of the system can be evaluated and a more relevant value attributed to the different options available.

Of these three phases of a control system life, it is by far the operation phase which distinguishes one vendor from the next, in terms of TCO. This is especially relevant at a time when our country is struggling to compete globally; when costs of labour, taxes and many other direct input costs here are higher than our global competitors. We need significantly more automation in order to reduce costs of production. Those companies which have made a significant investment in automation are more able to compete in the global marketplace than those which have fallen behind, and still rely on significant manual labour.

Replacement complexity, MTBF and MTTR Over the life of a system, components will need replacement due to fatigue, damage or obsolescence. It is also of value to consider what the anticipated lifetime of the machine will be. This will help to frame what considerations are of interest in the context of the analysed system. So it is important to consider not only the mean time between failures (MTBF) but also the cost and difficulty of replacement for the various components which make up the system, since some components will be simpler to upgrade than others. The reason for the second consideration is that at some point during the life cycle of a machine, a component will need to be replaced with a different model due to obsolescence. The effort required for this substitution will dictate extra measures or considerations which should be made at the design stage.

To illustrate this point, an example of PLC will be used as these devices are ubiquitously used throughout machinery. Since it is possible that the PLC will become superseded over the life of the machine, it would be worth considering the ability to re-use the program code in a new controller.

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This ability to re-use the program code in a new-model PLC should be of high importance; the cost to rewrite the machine program will far exceed the cost of the hardware replacement. Look for upward compatibility and a consistent use of the programming software across most models of PLC as well as simple model conversions.

Table 1 illustrates some typical MTBF data for various control system components.

It should be noted that one production year (for Table 1) has been calculated as 24 hours per day, 7 days per week, 52 weeks of the year (100% uptime). Note the actual lifetime of system components will be less than the above table due to power quality and other variables including operating temperature.

Direct costs during operation of the system can be considered as the most visible costs incurred. These are typically: • Initial purchase cost • Support or maintenance agreements • Software licensing • Training • Maintenance costs such as replacements • Electrical efficiency of the system Note that since all systems will consume electrical power, a relative comparison of electrical efficiency can be more useful than an absolute cost comparison.

While the initial cost of hardware may not be greatly dissimilar between different vendors, there is often a large divergence between solutions on the remaining direct input costs. Programming software (including upgrades) and technical support agreements can add significantly to the direct costs and are highly variable between vendors. Often over a period of five years or less, the cost of service agreements and software licensing can easily exceed the initial investment of the control system. This is especially important to smaller manufacturers, who still need software but have a smaller amount of hardware to amortise the costs over. How readily a vendor’s solution is supported is also worth considering, with obscure brands available at a lower price but which will likely end up costing more over time, due to limited support for the product, and limited support from system integrators and programmers.

Indirect costs tend to be less visible and will require more consideration. Examples of indirect costs can be the following: • Downtime and loss of production • Management of the software code and documentation • Replacement of obsolete components • Inherent latency in the system

OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Automation

Type

MTBF (hours)

MTBF (production years)

Medium PLC CPU

279,102

44.73

Servo driver

100,000

16.03

Micro PLC

105,118

16.85

HMI 7″ model

895,255

143.47

AC motor inverter

82,645

13.24

Table 1: Typical MTBF data for various control system components.

PLC scan time (ms) 1

2

4

6

8

10

5.015

5.030

5.060

5.090

5.120

5.150

6,288,335

6,269,583

6,232,411

6,195,678

6,159,375

6,123,495

0

18,752

55,924

92,657

128,960

164,840

Cycle time (s) Cycles per annum Extra cycles per annum

Table 2: Comparison of number of machine cycles based on a 24 hours/day, 365 days/ year production schedule.

Maintenance costs are slightly more difficult to estimate; however, there is data available to base decisions on. Here the MTBF data, obtained from manufacturers, is commonly available. Interestingly, some people are more concerned about mean time to repair (MTTR) than MTBF. Without doubt MTTR is of interest; however, if it is possible to repair a fault quickly (low MTTR) but fails often (low MTBF) it will be the MTBF which is the dominant consideration. Always take MTBF data as a higher consideration than MTTR. The warranty period is also of considerable interest at this stage of direct comparison. While failures range from rare to regular, it is important to assess this as it will impact the business greater as a loss of production than will direct hardware replacement cost. Failures outside of warranty have a three-fold cost: hardware cost, installation costs and production loss. It is often accounted for only as a hardware cost, especially when performed under a maintenance budget, but the major impact will be the loss of sales revenue, unutilised production floor labour and waste product.

Of course when a failure occurs, it is important to factor the actual losses a business will incur into the cost of this failure.

Production rates ranging from $1K to $50K per hour (based on value of goods sold) are typical, with even higher rates possible when considering automotive or aerospace

industries. Often, it is a matter of only one hour of lost production which can produce losses greater than the difference in cost of proven quality control system components and lower cost, low quality components. Even warranty periods for equipment vary greatly, with some suppliers offering twice the warranty period of others; a manufacturer’s confidence in their product is demonstrated by the warranty period offered.

Control system latency Latency is a measure of the time delay in a system. All digital control devices inherently have latency due to the cyclic evaluation of a program and responses to changes of inputs. The size of the program, the use of tasks and interrupts and the processing power of the CPU all affect the rate at which the system will respond to a change in machine state.

This latency is a source of a hidden cost in manufacturing. The slower a particular control system is to process the user program, the slower it reacts to changes in input states. Although this is often measured in milliseconds, when accumulated over the many cycles per annum, this time can add up to be equivalent to weeks of production time.

There is a large discrepancy between vendors when it comes to cycle times, with some manufacturers achieving cycle rates in the order of 10 times faster than others.

6 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

The fastest controllers are generally those used in controlling machinery, where quick update rates are paramount. This acts to slow down a production line, and the faster the cycle rate of the machine, the more this latency affects efficiency. However, since this is measured in tens to hundreds of milliseconds per cycle, it must be considered over the period of a production year to evaluate quantifiable differences.

To illustrate this effect, consider a generic machine control algorithm; sequential control by state transition. This sequence consists of five pneumatic cylinders controlled by a PLC, each cylinder having an extended and retracted proximity switch. Each cylinder will be extended, and a proximity sensor is used to trigger a change in PLC state, which commands the next cylinder. Once all cylinders are extended, they begin retracting, one after the other in a similar manner.

Each proximity input causes a transition in the state of an output.

The timing of the reaction to the input and change of state of the output is related to the cycle time of the PLC. It can be assumed that the change of state of the input will occur on average halfway through a PLC cycle; hence the time taken to update the output will be 1.5 PLC scans (half a scan to read the input as on and another scan to update the output). If each cylinder extends or retracts in 0.5 s, then we can evaluate the PLC latency and effect over the course

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Automation

WHILE THE INITIAL COST OF HARDWARE MAY NOT BE GREATLY DISSIMILAR BETWEEN DIFFERENT VENDORS, THERE IS OFTEN A LARGE DIVERGENCE BETWEEN SOLUTIONS ON THE REMAINING DIRECT INPUT COSTS.

of one manufacturing year. The results are shown in Table 2.

As can be seen in the Table 2, the difference between a fast 1 ms PLC scan and a slower 10 ms scan can be almost 165,000 machine cycles per annum. As each machine cycle is 135 ms faster, it will not require additional labour to operate; this is effectively increasing the throughput of the machine.

The above example shows the hidden cost of latency which exists in almost all production lines. The benefits are easy to realise over the course of one year.

The cost of a faster CPU will have a very short return on investment (ROI) for fast 180wx135 ensure

10/9/13

11:31 AM

cycling, transition-dependent machines.

PLC manuals should contain processing times for specific instructions, as well as overhead time for peripheral servicing and I/O updates, and be wary of any system which does not make these times clear.

Summary When comparing industrial automation systems, most consideration tends to be incorrectly given to the initial cost. But it can be readily seen that this initial cost is the least consideration when it comes to analysing the true cost of an automation control system. Ongoing costs, such as product support, software licensing Page 1

agreements and control system latency represent a much larger proportion of the overall cost than the initial purchase price. Not all PLCs are the same, and a very large discrepancy between cycle times can be found. When comparing data between different vendors, make sure to consider the mean time between failures and give appropriately more importance to this than the mean time to repair. Be wary of ongoing costs and consider their impact to the overall cost of the system.

Omron Electronics Pty Ltd Contact info and more items like this at wf.net.au/V058

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

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

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

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

Spraying Systems Co.

PTY LTD

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

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

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OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

EX I ISOLATOR RANGE R. Stahl has extended its ISpac family of Ex i isolators with the 9147 series. The transmitter supply units enable the use of vibration sensors in hazardous areas. These sensors for condition monitoring of plants and machines allow users to detect any damage at an early stage.

Most vibration sensors are designed with the protection class Intrinsic Safety (Ex i) and require the use of isolators. The 9147-type supply units support a wide range of these sensors and transmitters.

An easily accessible rotary switch allows for quick and easy configuration. Two versions are available: a one- and a two-channel version. The two-channel version requires 50% less space in the switching cabinet, which may reduce indirect

TOUCH-SCREEN DATA LOGGER

installation costs. An optimal signal-to-noise ratio ensures precise signal

The ALMEMO 710 touch-screen data logger

transmission. Like all ISpac isolators, the modules are available as single units

from Ahlborn can connect to and evaluate

on a DIN rail, with a common power supply and collective error message via the pac-Bus,

all new (D7) as well as existing sensors. The

or in pac-Carriers. The pac-Carriers enable factory prewiring of plants, thus facilitating final

ALMEMO V7 connectors allow it to process up

mounting or retrofitting at a later date and ensuring error-free installation of the isolators.

to 10 channels for measured values, including

The detection of problematic vibrations is important in condition monitoring of process

multivalue sensors and external devices such

plants with rotating parts. By diagnosing danger before a failure could happen, it helps

as complex chemical analysers and energy

prevent plant shutdowns. Generally, vibration detection is successful earlier than temperature,

analysers.

speed or acoustic measuring. Complete condition monitoring for machines also includes

Sensors using analog signals pass via the

temperature sensors, discrete signals and 4-20 mA signals.

integrated high-speed, high-resolution A/D

R. STAHL Australia Pty Ltd

converter. Digital D6 and the latest digital D7

Contact info and more items like this at wf.net.au/U873

sensors transfer their measured values to the measuring instrument direct in digital form. The measuring instrument supports all ALMEMO

HIGH-CAPACITY BRAKES Nexen’s dual-faced brakes (DFB) and quad-faced brakes (QFB) are designed for heavy-duty industrial power-off applications that require high torque and low inertia.

The high-capacity, spring-engaged brakes are intended for applications such as conveyors, punch presses, shears, mills, rock crushers and similar equipment.

The brakes require minimal maintenance and help save costs. A simple piston and cylinder actuator is sealed with easily serviceable O-rings that reduce maintenance costs when compared to actuators that incorporate large, expensive air bladders. The brakes are engineered with segmented, non-asbestos friction facings for easy replacement and free-flow cooling air. Low-inertia friction discs minimise load deceleration time. The dual-faced brakes are engineered with a single-disc assembly, and the quad-faced brakes have a double-disc assembly.

Both brakes are designed for efficiency. Torque is transmitted through friction discs and splined pressure plates, which maintain good alignment and low frictional resistance, the two contributors to fast engagement and disengagement. Efficient O-ring and interface cooling is possible because of the brakes’ fins and air passages. The brake housing is flange mounted to machinery and the hub is keyed to the shaft. Cylinder inlet ports provide direct air supply.

Norman G Clark Pty Ltd Contact info and more items like this at wf.net.au/V033

8 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

plug connectors and sensor functions. Digital D6/D7 sensors can be configured directly via the touch screen. Measured values can be displayed with up to eight digits (depending on range) and the units with up to six characters. Sensor designation can be up to 20 characters.

The ALMEMO 710 has a bright 5.7″ colour display for all measured values and functions and is equipped with a software wizard and online help via pop-up windows. Measured, peak, average and limit values can all be displayed in various forms, namely list, bar chart or line graph (up to four lines). Users can also configure their own customised user menus to display those parameters required by a particular application. The ALMEMO 710 can be rail mounted to suit both fixed and mobile applications. Data can either be stored in an 8 MB flash memory or on a plug-in micro SD card that allows 1000 measurements/s measuring speed and for autonomous long-term monitoring.

Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/U951

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HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

>

>

SAFETY ISOLATORS

TEMPERATURE TRANSMITTER

The SSX and SST safety isolators and splitters provide reliable

ifm efector has released a temperature transmitter with

isolation and signal conversion for HART data.

a bright 4-digit display and IO-Link for food applications.

Moore Industries Pacific Inc

ifm efector pty ltd

WF.NET.AU/U798

WF.NET.AU/V008

>

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

MODULAR MODBUS I/O SYSTEM

technology.

Phoenix Contact Pty Ltd

WF.NET.AU/V009

PROBUS is a modular Modbus

>

I/O system that provides a simple, low-cost solution for distributed I/O requirements.

Procon Electronics Pty Ltd

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COMBINED LIGHTNING AND SURGE ARRESTORS The DEHNvenCI is a combined lightning current and surge ar-

>

rester with a discharge capacity up to 25 kA in a single device.

DEHN + SOHNE GmbH + Co KG

WF.NET.AU/V059

10 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW PRODUCTS

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TOXIC GAS DETECTOR WITH IECEX APPROVAL The TS4000H intelligent toxic gas detector from General Monitors is now IECEx approved, and offers protection against a wide range of hazardous industrial gases and is able to safeguard against oxygen deficiency.

The toxic gas detector offers event logging, a clearly visible LED, and an indicator for remaining sensor life. The device is compatible with the HART communications protocol for uniform and consistent communication without disturbing the integrity of the 4-20 mA analog signal, and is also available in a Modbus configuration and with three 8 A relays. All of the electronics are contained within an explosion-proof housing so that sensor information can be processed at the sensor site.

The interface module’s galvanically isolated, intrinsically safe design supports sensor field replacement without special tools or hot work permits. The detector is easy to install and can self calibrate by activating a magnetic switch and applying gas. The device is suitable for a broad range of industries, including petrochemical installations, oil and gas production facilities, water and wastewater treatment sites, and power plants. The detector also complies with ATEX, CSA, CE, GOST in addition to IECEx, and is certified for use in SIL 2 environments.

The toxic gas detector monitors a variety of toxic gases such as am-

(IRSCHMANN %!',% 4OFINO THE FOUNDATION OF YOUR DISTRIBUTED @DEFENCE IN DEPTH NETWORK SECURITY STRATEGY

monia, carbon monoxide, chlorine, chlorine dioxide, hydrogen, hydrogen

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needed, and provides complete status to the control room.

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chloride, hydrogen sulfide, nitric oxide, nitrogen dioxide, oxygen deficiency, ozone and sulfur dioxide. The system displays gas concentrations up to 500 ppm, fault codes for troubleshooting, prompts when calibration is Aquip Systems Pty Ltd Contact info and more items like this at wf.net.au/U792

UĂŠ iÂ˜ĂŒĂ€>Â?ÂˆĂƒi`ĂŠ >˜>}i“iÂ˜ĂŒ UĂŠ >ĂƒĂžĂŠĂŒÂœĂŠVœ˜vˆ}Ă•Ă€iĂŠĂœÂˆĂŒÂ…ĂŠÂź i>Ă€Â˜Â˝ĂŠvi>ĂŒĂ•Ă€i UĂŠ iiÂŤĂŠ*>VÂŽiĂŒĂŠ Â˜ĂƒÂŤiVĂŒÂˆÂœÂ˜ĂŠEĂŠ->Â˜ÂˆĂŒĂžĂŠ Â…iVÂŽ

SOLENOID VALVES FOR OIL BURNERS BĂźrkert has developed a range of shutoff valves for the different performance

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classes and types of oil burners. In addition to applications such as shut-off, forward flow, return flow and circulation valves, the full range of diameters and the use of sealing materials with high thermal and chemical resistance to media open up a broad spectrum of applications for Types 5406, 5407, 6027 and 6213. The bodies are manufactured

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from brass or stainless steel, depending on the type and size. A universal top-mounted coil system with protection class IP65, as well as optimised and adapted voltage ranges, make this line of safety shut-off valves for oil burners cost-effective due to low inventory requirements and a high service level. The solenoid valves are TĂœV-certified in accordance with DIN EN ISO 23553-1 and have been certified by DIN CERTCO.

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Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/V137

12 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW PRODUCTS

ENCAPSULATED LED AREA LIGHTS The Banner Engineering WLA Series encapsulated area lights are designed for use in industrial environments. These powerful, solid-state LED lights are completely encapsulated in optically clear polyurethane - enhancing chemical compatibility and increasing their resistance to shock and vibration.

The encapsulated WLA light is a rugged, highintensity light ideal for machine lighting, visual inspection stations and general industrial area lighting. The sealed light is available in four sizes and has a sleek

HYDRAULIC COUPLINGS FOR MINING

polycarbonate housing and slim profile.

Snap-Tite’s 75 Series and 59 Series couplings are designed for high-pressure hydraulic service.

The 75 Series couplings are engineered to be used in heavy-duty applications with mobile equipment, oil and gas drilling, cranes, reels, pumps and power tools as well as water transfer lines and power units. Connection is through a screwtogether style designed to shut off automatically under normal conditions in both the coupler and nipple halves when the unit is disconnected.

The rugged design and high-strength materials mean the units can be used in abusive situations. Units are available in stainless steel or steel with zinc trivalent chromate plating that resists corrosion. A choice of seal materials means the 75 Series is able to handle a variety of applications including the use of fire-resistant fluids. Snap-Tite Series 75 are available in Firesafe versions as specified in API 160

Featuring a maintenance-free design, the energy-

and EUB directive #36 for use of blowout prevention (BOP) circuits.

efficient Banner WLA encapsulated area lights are de-

Series 59 is a thread-to-connect quick-disconnect coupling that allows connection

signed to withstand high-pressure, high-temperature

and disconnection while under pressure due to its threaded design and patented

washdown applications and are rated to IP69K. Easy

internal valve system. Suitable for any pulsing or hammering equipment, an optional

installation options include quick disconnect or cable

snaplock feature is available if pulsating flows tend to unscrew couplings due to

versions, a versatile angle bracket and a magnetic

hose flex. Backpressure is low and heat generation is kept to a minimum. The

mount solution.

coupling is a no-spill, drybreak, flat-faced design that keeps the workplace free of

Micromax Pty Ltd

spillage. The unique Acme thread fully connects in one-third the turns of similar

Contact info and more items like this at wf.net.au/V031

couplers while remaining dirt tolerant.

Norden Hydraulic Connections Contact info and more items like this at wf.net.au/U899

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OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

NEW PRODUCTS

OXYGEN ANALYSER The XZR200 is capable of measuring percentage oxygen to better than 1% of span (or 0.5% O2) with ranges of 0-25% and 0-100% available. The analyser is easy to install and integrate into existing systems as no specialist software is required; the RS232 output can be accessed via a PC. The analyser offers four configuration options, with two choices of probe length and two temperature ranges. The lower temperature range (up to +250°C) is suitable for relatively low-temperature applications such as food and drink packaging, while the higher temperature range of up to +400°C serves combustion control and metal treatment applications.

Depending on the application, the analyser may also be configured to measure in either 0-25% or 0-100% oxygen concentrations. The first configuration gives the highest accuracy of 0.5% O2 in the combustion process range. In the 0-100% range the accuracy is 1% O2.

A key feature of the analyser is a 3.3 VDC logic output which is used to monitor the sensor for diagnostic purposes. It enables the operator to check on the health of the sensor, providing a warning if there is a fault with the sensor. The life span of the zirconium dioxide sensor is between 1 and 7 years.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/U900

WASHDOWN DUTY DRIVES Dart Controls has developed the 125DV200E DC drive for washdown applications. Two NEMA 4X enclosures are available: black and white, with speed and direction controls right on the outer panel where they are needed.

The 125DV drive carries all the features found in now obsolete and difficult-to-find older drives, but built with all current componentry.

The dwindling number of DC drive suppliers has made it difficult to find suitable and adequate replacements for legacy drive brands that are still widely used in industry today. With six standard models incorporating on/off, forward/ brake/reverse and run/job settings, the 125DV has all the features of DC drives in an up-to-date package for motors in the ¼ to 2 hp range. Acceleration, deceleration and current limits are all adjustable, giving full motion control.

The drives can be configured and customised to suit the application.

Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/V014

VERTICAL NETWORK BOOT BAR The Western Telematic NBB-20VD16-3 vertical mount switched PDU is a high-amp, switched PDU specifically designed to provide secure, remote power control and reboot capabilities for high-density rack enclosures.

The device features dual 16 A inputs, 20 remote switched IEC C13 outlets and four 16 A UL489 circuit breakers. Each circuit breaker protects five IEC C13 outlets and supports up to 16 A. The device is built for vertical 0U installations where rack space is limited. Mounting kits are available to fit a variety of rack and closet enclosures.

The device includes a robust selection of monitoring features, including event alarms and SNMP polling to help keep tabs on vital network elements, avoid costly service calls and maximise uptime.

The device can also perform reboots and power shutdowns on individual outlets according to a user-defined schedule. It can monitor the ping response from critical equipment and if a ping command fails it can automatically reboot the device. The NBB-20VD16-3 can be configured and operated via its IP web browser interface or by any SNMP MIB-based enterprise management software.

Interworld Electronics and Computer Industries Contact info and more items like this at wf.net.au/U868

14 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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CASE STUDY

Smart software overcomes design challenges for Australian oil and gas project What links together sour gas and declining fuel pressure tailing life of the well," explained Nathan Smith, Engineering in the oil and gas industry? Well, they’re just two of the Manager - Process at WorleyParsons Hydrocarbons. challenges in major projects that Australia’s biggest contractor, The intuitive user interface of Aspen HYSYS is a drawcard.

WorleyParsons, has grappled with in recent times.

WorleyParsons are able to train a range of employees to use WorleyParsons recently won a contract with BG Group’s $20 the software with a fairly good degree of accuracy very quickly. billion Curtis LNG facility in Queensland and new CEO Andrew “Also, the level of definition is good; we can apply things like Wood is proud that his company is one of the few that can do discrete pressure drops across specific unit items,” explains major-project end-to-end delivery.

Smith. “It’s very easy to set up pipe segments and model A key strategy behind much of WorleyParsons’ success is pressure drops, so it has the functionality yet the intuitive embracing all five phases of the project asset life cycle - identify, interface.” evaluate, define, execute and operate. Supporting this strategy Aspen HYSYS can also be combined with products from is a suite of products from AspenTech. In 2003, WorleyParsons other companies, as was the case in a subsea project on deployed core AspenONE Engineering applications, Aspen which WorleyParsons were the engineers. As it emerges HYSYS and Aspen Basic Engineering (ABE), at four global from the well, water contained in natural gas mixes with design centres. the sour component of the T h e i n i t i a l fo c u s w a s gas (high concentration of on basic simulation and H 2S) and condenses, due to the production of process the cooling from the subsea flow diagrams (PFDs), data environment. This can then sheets and equipment list corrode the upstream section d e l i ve ra b l e s , a s w e l l a s of the carbon steel pipeline. the importing of heat and WorleyParsons used Aspen material balance data from HYSYS in combination with a conceptual design. After an CFD modeller package from initial test, the AspenTech another vendor to model a solution was expanded and subsea cooler made out of used on increasingly large and a corrosion-resistant alloy. complicated projects.

A length of corrosion-resistant One of the tools employed alloy was placed subsea near for the Curtis Island project the gas well, just sitting on top was Aspen HYSYS (Aspen of the seabed.

Process Modeller), which CFD of subsea cooler and outside heat transfer coefficient.

The gas is cooled such that introduced the approach of steady state and dynamic simulations in the same platform.

The data from Aspen HYSYS is integrated into Aspen Basic Engineering (ABE) then maintained in a single, up-to-date central repository and shared by all team members. HYSYS information is automatically interfaced into ABE, eliminating any data redundancy and recapturing errors.

WorleyParsons used this to model a gas processing train where there was a declining inlet gas pressure. The challenge was to determine how much flow could be pushed through the gas processing train as a function of the declining inlet gas pressure. The team outlined the capability of the export compressors, because those were viewed as a potential bottleneck. By modelling the compressors in Aspen HYSYS with data such as export pressures or discharge pressures, they were able to build the model to the requirements at the front end of the plant. This included modelling elements like gas heat exchangers, low-temperature separators and inlet separators. The team was therefore able to generate pressure drops through all of those equipment items as a function of inlet conditions such as inlet arrival pressure and flow rate.

"Ultimately we were able to grow the operating envelope, not just from the compressor set but from the entire gas train, then marry that up with the deliverability of the gas wells to tell the customer how much gas they were able to process over the

16 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

the rate of condensation under water is dramatically reduced below 50°C. Once the gas was cooled down to less than 50°C, it was possible to run that gas in a carbon steel pipeline going to the gas plant onshore, because there is going to be far less condensation of the water and little or no corrosion.

“We used HYSYS to model the forced convection heat transfer effects inside the subsea cooler,” explains Smith.

“We used computational fluid dynamics from another package to model the natural convection effects of a hot pipe spool under water.”

The seawater absorbed the heat from the gas and, by pairing up Aspen HYSYS with the CFD modeller, the WorleyParsons team were able to design the length of spool required to cool the gas from its 90°C flowing temperature to below 50°C. A mechanical subsea cooler has since been designed and installed.

“The well is going to be starting up shortly," notes Smith, "and we’re all keen to see how that subsea cooler performs.”

A longer version of this article can be read online at http:// www.processonline.com.au/case_studies/62598-Smart-softwareovercomes-design-challenges-for-Australian-oil-and-gas-project.

Aspen Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/V073

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NEW PRODUCTS

UNIVERSAL SURGE ARRESTORS Available in different voltage levels, the BXT ML2 surge arrestor modules provide optimal protection for measuring and control circuits,

ULTRASONIC LEAKDETECTION CAMERA

bus systems, alarm systems and telecommunication systems. No matter if

The Leakshooter LKS 1000 is

cable shields are earthed directly or

claimed to be the first camera to

indirectly, BXT ML2 protective modules

detect, measure and photograph air

can be used for any application.

and vacuum leaks. It provides the dual

If, for example, direct shield earthing

possibility of ultrasonic leak detection with

is not possible, the two-pole module

a visible image. This enables users to see,

allows for indirect shield earthing which

on a large LCD colour screen, the precise

is capable of carrying lightning cur-

location of air and vacuum leaks. Once

rents. Indirect shield earthing prevents

near a leak, a dynamic target will appear

undesired equalising currents due to

and change in size and colour from yellow to red depending on the severity of the leak. At the bottom of the screen, the continuous measurement of dB RMS and MAX is displayed on a colour bar graph.

having the gas discharge tube connected to earth potential.

A universal base part, which is standard for all BLITZDUCTOR arrester modules, optimises storage and allows for prewir-

Once facing a leak it is then possible to take a picture of

ing and commissioning. The design of the arrester allows for hot

the precise leak location. The camera can store up to 1000

swapping at the touch of a button without interruption of signal.

pictures in JPEG format. All pictures show date, time, dB level

The protection module snaps into the base part and is prevented

and can be numbered manually. The pictures can be transferred

from becoming loose.

to a PC with the Leakviewer software.

Since no electronic components are installed in the base section,

While operating the camera, the possibility to lis-

only the actual protection modules have to be monitored and main-

ten to the leak noise with headphones is still possi-

tained. With maintenance testing of the arresters by means of the

ble. The operator is then, for the first time, able to see

RFID LifeCheck system, the module does not have to be removed.

what he is listening to. The camera detects a leak of

Each BLITZDUCTOR XT module has an integrated RFID. The

0.1 mm with a 3 bar (300 Kpa) pressure at a distance of

LifeCheck arrestor testing system constantly monitors the status

20 m. There is adjustable gain of 50 to 110 dB for use in any

of the arrester, which can be read out via DEHNrecord LC via the

kind of surroundings.

contactless RFID technology. BLITZDUCTOR XT also has an exten-

There are accessories available for use with the camera,

sive range of accessories such as elements for labelling, earthing

including a probe for identifying noisy bearings, steam traps

modules for unused cores or an easy testing module for circuit

and solenoid-operated valves.

testing without having to disconnect connected wires.

Cope Air Technologies Pty Ltd

DEHN + SOHNE GmbH + Co KG

www.copeair.com.au

Contact info and more items like this at wf.net.au/U864

18 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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Integrated safety solutions at your doorstep When it comes to safety, NHP combine expert people with an extensive range of products and services from leading global suppliers to deliver integrated, valueadd solutions. It’s all a part of our customer promise to be easy to do business with.

In addition to these partnerships including Rockwell Automation and the Allen-Bradley® range, our IECEx certified Hazardous Area Workshop offers the ability to customise solutions to suit project specific application. Bringing together individual safety components, NHP has the knowledge to design integrated solutions that offer increased control across your operations.

Calling upon our safety team which includes TUV certified experts, we can also offer a range of services and training opportunities to ensure you are up-to date with the ever evolving machine safety industry.

For increased convenience, this same team can also provide onsite consultation and risk assessments for site specific applications.

If you’re looking for an advantage when it comes to safety, the safe choice is NHP. For more information on our On Tour programs please visit nhp.com.au/Media/Events/On-Tour

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A HOLISTIC APPROACH TO CONVEYOR BELT MONITORING A HOLISTIC APPROACH TO CONVEYOR BELT MONITORING Neil Freeman, Principal Consultant, Honeywell Process Solutions

Neil Freeman, Principal Consultant, Honeywell Process Solutions

20 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER OCTOBER 2013 2013

www.ProcessOnline.com.au

Materials handling

Conveyor systems play a major role in in the mining, minerals and metals industry, and unexpected downtime can be costly - but now there is technology that enables continuous monitoring of conveyor assets that can reduce maintenance costs and improve uptime.

I

n the mining, minerals and metals industry, it is often thought that materials handling begins where processing ends and therefore does not have a significant impact on overall quality and value. However, the transportation of materials is a critical piece of the production process and can significantly impact the overall cost-effectiveness of an operation, especially if a system should fail. Central to the transportation systems of many mining and plant facilities is the conveyor belt, a seemingly low-cost and low-priority piece of equipment in the supply chain. Yet from a maintenance perspective, conveyors can cause substantial setbacks to operations if left unchecked and can be costly to maintain.

Traditionally, routine maintenance and monitoring of conveyor systems has been a low priority for operations. This is because usually, what are considered more urgent matters take precedence, such as pumps and mills. But it is also partly because conveyors often stretch for many kilometres, in remote locations that aren’t easily accessible by foot or vehicle. Typically, operators tend to wait until there is a fault with a conveyor and then conduct maintenance or replace on a timed basis (such as in the case of idlers) in the hope of avoiding failures. But the challenge with this approach is that unplanned downtime can result in catastrophic production and financial losses.

The cost of unplanned maintenance In today’s increasingly cost-conscious manufacturing environment, companies are under greater pressure to improve equipment reliability to achieve operational objectives and reduce maintenance costs. Central to an efficient operation, however, is achieving a high level of capacity utilisation, with plants needing to make the best use of their existing capacity. By measuring overall equipment effectiveness (OEE), plant managers can identify gaps between ideal and actual operational performance. These issues, comprising quantifiable OEE gaps, can be converted into the tactical and strategic steps that influence productivity, which can significantly impact overall business results. And at sites like mines, ports, cement plants and iron and steel mills, materials handling can constitute a major contributor to the overall business results.

Transporting products like iron and coal using conveyors is tough on these systems, resulting in the need for continuous maintenance and parts replacement. But scheduled maintenance on conveyors can easily fall to the last priority, as it is often labour intensive and difficult to monitor all areas, regardless of good intentions.

The process of belt inspections typically involves a maintenance staff member, who walks the length of a belt to visually inspect for faults, or in some cases, drives alongside it. But when conveyor belts can be up to 50 kilometres long and in hard-to-reach

www.ProcessOnline.com.au

locations, such as at high altitude in tunnels through mountains, this monitoring can be difficult to deploy. Such an environment makes it near impossible or expensive to adopt traditional conveyor monitoring techniques.

But correlating with the drop in preventative maintenance can be a rise in shutdowns and unplanned downtime. Some operations have reported that conveyor outages account for up to 50% of their unscheduled disruptions. So when a shutdown could easily result in hundreds of thousands of dollars in lost production per hour, it is essential that conveyors operate as efficiently as possible, with maximum availability to an operator.

Past approaches There are a number of existing monitoring solutions that address specific aspects of a conveyor system, but none of these offer operators a complete picture of the health of their conveyor belt.

Typical ‘point’ solutions can provide details about specific areas of the conveyor belt but may not assist in prioritisation or integration with other point solutions. In an increasingly resource-constrained environment, operations should consider the benefits of an integrated solution, combining measurement technologies with decision support capabilities, for optimal conveyor health.

Managing the health of conveyor belts is complex, with numerous measurement requirements for complete monitoring of the system.

This includes the detection of cover defects, edge damage, belt rips, pulley health, belt wear, internal defects, wander and steel cord damage. It also involves monitoring for drive health and idler health, as well as material off-loading and chute blocking. Moving from an ad hoc approach to conveyor monitoring to an online and integrated conveyor belt management system requires careful planning and a methodical approach.

A holistic approach While point solutions may have been a reasonable approach to monitoring systems in the past, increasing cost pressures and shortages of skilled resources necessitate a more streamlined and efficient approach. An effective and holistic conveyor health monitoring solution extends the service life of a conveyor system and proactively identifies areas in need of attention before operations are impacted. This ultimately contributes to saving a company time and money by better managing resources and avoiding a costly shutdown affecting production.

New industrial technologies, like Honeywell Process Solutions’ recently introduced BeltAIS (Belt Asset Inspection System) suite, allow operators of mining, minerals and metals facilities to minimise the impact of conveyors on their overall equipment effectiveness.

OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

Materials handling

They are designed to detect, monitor and report on the health of the conveyor belt and associated components. With visibility into the actual health status of conveyor equipment, users from operations, maintenance, reliability and other departments can gain a consistent understanding, enabling effective planning and execution of maintenance.

Holistic solutions minimise the total cost of ownership of conveyors by improving maintenance predictability and reducing operational downtime due to faults. They also reduce labour costs and allow staff to address more critical maintenance issues. For example, rather than rely on multiple standalone monitoring solutions, users can employ such a solution to maintain a continuous, online view of all conveyor maintenance requirements and perform a wide range of monitoring and analysis functions. Such systems not only integrate numerous systems, but provide an intuitive, user-friendly interface to the conveyor that improves the effectiveness of plant maintenance and operations personnel.

Better-timed maintenance With pressures to cut maintenance costs to improve profitability, a different approach to maintenance can also result in significant savings for operations. Traditionally, all maintenance and monitoring has been conducted in-house, placing considerable strain on resources. This can result in less critical maintenance activities being deferred or not done, increasing operational risk. Thus, rather than deploying a continuous conveyor defect monitoring solution, users have the option of rotating the monitoring solution across a number of belts in operation. For example, deploying the technology monthly across each belt can give operators a clear picture of the rate of degradation and the frequency required for belt replacements or maintenance activities. Operators can also elect to operate such a solution as an outsourced service.

Learnings across industries The first solution in Honeywell’s BeltAIS suite is the BeltAIS Cover Defect Monitoring System. It is a video-based decision support tool

22 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

designed to perform repeated defect analysis of a conveyor belt’s surface. This helps to identify potential risk zones and assist in degradation analysis, upon which further action can be initiated.

While continuous monitoring of belt defects is a new concept to the mining, minerals and metal industry, it’s a technique that has been tried and tested in pulp and paper manufacturing. The same camera-based solution is used in the pulp and paper industry to monitor for defects in the papermaking process. In that environment, small defects (less than a few millimetres) introduced during manufacture can result in a catastrophic loss of product. The location of tears and other defects can be narrowed down to within centimetres and tracked through the paper machine. This technology has been adapted and updated with tailored algorithms to make it as effective in the harsh environment of resource extraction. The system provides a metre-by-metre analysis with video images for later retrieval and review.

Materials handling may begin where the traditional processing operation ends; however, this is a part of the supply chain that can have significant impact on the overall cost-effectiveness of an operation. And in the mining, minerals and metals industries, conveyor belt systems can contribute a significant part of unforeseen maintenance costs, which can usually be avoided through a comprehensive predictive maintenance strategy.

By deploying a holistic solution to conveyor maintenance, users can expect to achieve noteworthy cost savings through better planning and a reduction of downtime. Operators can also reduce replacement costs through more timely and strategic maintenance, and minimise an unnecessary amount of maintenance through more insight into the rate of degradation unique to each operating belt.

Automated and online monitoring also reduces the need for manual inspection, reducing labour costs and allowing staff to address more critical issues. Finally, a reduction of catastrophic belt failures will significantly impact a company’s bottom line.

Honeywell Limited Contact info and more items like this at wf.net.au/V144

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9–10 APRIL 2014 | MELBOURNE PARK FUNCTION CENTRE, MELBOURNE OLYMPIC PARK

CALL FOR PAPERS Join us for the inaugural ACI Connect conference and exhibition where key personnel drawn from a wide range of industry sectors including food and beverage, resources, manufacturing, utilities and chemicals, along with system integrators and consultants, will gather to hear from experts and share ideas to help develop their expertise.

Research is underway and the conference production process has begun, offering you the opportunity to share your thoughts, experiences and insights — we are now seeking case study proposals for inclusion in the conference agenda. If you would like to share your knowledge and practical experience with this audience, we would like to hear from you.

The aim of ACI Connect is to allow industry and users of automation, control and instrumentation systems, products and services to share experiences, develop ideas and to hear best practice from those who understand the real challenges faced day to day.

Key focus points for ACI Connect 2014: • Automation • Control • Instrumentation

Case studies from, but not limited to, the following sectors will be considered: • Food and beverage manufacturing and processing • Mining, minerals and metals processing • Power generation and distribution • Water collection and distribution • Chemicals manufacturing and processing • Oil and gas exploration production and distribution

ABSTRACT SUBMISSIONS CLOSING DEADLINE: 31 OCTOBER For more information contact Lisa Crossley at events@ACIConnect.com.au, or phone 02 9487 2700, or download the Call for Papers from http://www.westwick-farrow.com.au/pdf/ACI_call_for_papers.pdf

Association Partner:

Training partner:

Magazine partner:

Organised by:

WFevents, a division of Westwick-Farrow Media - ABN: 22 152 305 336

CASE STUDY

Safety inspection prompts crane upgrade at Bayswater Power Station To comply with safety requirements, Macquarie Generation’s Bayswater Power Station underwent a routine inspection of its aging cranes. As a result, the company called on the domain expertise of Rockwell Automation to deliver a solution for the cranes to meet current safety standards.

The Bayswater Power Station, in the Upper Hunter Valley area of NSW, is one of two stations owned and operated by Macquarie Generation. Each year the company produces approximately 13% of the electricity required by people in eastern Australia, making Macquarie Generation one of the country’s largest electricity generators.

Bayswater's design reflects the progress and improvements in power-generation technology to maximise efficiency and minimise environmental impacts. The most distinctive feature of Bayswater Power Station is the four evaporative cooling towers.

Over recent years, Bayswater Power Station has produced approximately 15,000 GWh of electricity a year. This is enough power for two million average Australian homes.

Following a mandatory 25-year inspection, Macquarie Generation recognised that two of the station’s overhead cranes required upgrades to their drive systems to meet current Australian safety standards and to address obsolescence issues.

With a commitment to the improvement of operation and technology upgrades, Macquarie Generation called on the expertise of the Rockwell Automation Solutions team to project manage, design, manufacture, install and commission a solution to meet the company’s requirements.

The primary role of the cranes is for use during generator shutdowns, which take place once or twice a year depending on what is required when work is suspended.

According to Peter Tomazic, Solutions Consultant for Rockwell Automation, “The primary role of the cranes is to lift equipment in and out, as required, during outages. When the power station is running normally these cranes generally sit idle.”

Designing a cost-effective solution to customise the electrical system to fit through the manholes of the existing crane structures presented some unique challenges that would call on the risk management expertise of Rockwell Automation.

During the risk assessment it was found that the cranes’ access manholes were not large enough to allow installation of standard gear plates or new control cabinets.

“We discovered, post audit, that we would be putting the new solution into a very crammed electric house,” said Tomazic.

The crane drive systems are usually pre-installed in cabinets and the existing electrics had all been mounted into the frame of the crane, so that access into it was much like a ship hole door. It appeared as if, when the cranes were originally built, there was a bigger opening and the manufacturer had then built around it.

“As a result of this, we had to cross off an earlier idea to design entirely new cabinets, which would have made the job much easier,” said Tomazic.

“Instead, we decided to manufacture the insides of the electric drive cabinet in a manner that could be brought into the existing crane electrics and fitted into the existing cabinets once they were gutted.”

Rockwell Automation provided a custom-designed and manufactured solution consisting of GuardLogix and PowerFlex DC drives mounted on custom-built gear plates for installation in the original crane cabinets. The challenges presented in this project required something that was not simply an ‘off-the-shelf’ solution.

24 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

According to Tomazic, “We are often awarded contracts that require our engineers to ‘scratch their heads’ a little bit to come up with the best solution. Our local engineering team manages many upgrade projects to help reduce the customer’s risk, supplying projects on time and within budget.”

Once the obstacle of a ‘crammed’ electrics house was overcome

by Rockwell Automation, Macquarie Generation was able to realise the outcomes it was expecting.

The GuardLogix controllers allowed safety to be integrated into the system, and addressed what was required by current Australian safety standards for these applications. The solution also incorporated an innovative data-logging capability within the GuardLogix system using the Historian ME module.

“The cranes’ operating data was previously difficult to record with the obsolete analog system, so to fix that we provided a solution that was capable of logging the operating data of the cranes, which the company required for tracking crane usage,” said Tomazic.

The key outcome from this project is that it has reinvigorated Bayswater Power Station’s two cranes to safely and reliably take the station through many more outages.

Along with both cranes now adhering to current Australian safety standards, the design offers a fault-tolerant system that does not compromise the safety of the crane in the event of a single failure.

According to Satish Busuapala, Acting Team Leader at Bayswater Power Station, “The project, awarded to Rockwell Automation in October 2011, took about a year to complete and Macquarie Generation is very pleased with the outcome.”

“The cranes, they have been performing well since the upgrade,” he continued.

Rockwell Automation attended to the whole life cycle of the project from the safety-risk assessment, to the design, manufacture and commissioning of the project.

“We needed to have the cranes certified for them to be at current standards and Rockwell Automation achieved that for the power station. Macquarie Generation would have no hesitation in working with Rockwell Automation again as further upgrades are required,” concluded Busuapala.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/V068

www.ProcessOnline.com.au

NEW PRODUCTS

ADJUSTABLE PRESSURE SWITCH WIKA has expanded its range of OEM pressure switches with the Model PSM03, which provides an adjustment knob, allowing the switch point for the model to be set continuously.

The compact instrument enables the user to choose between two process connections - mounting thread or flange. In addition to the increased installation flexibility, the pressure switch has a long service life, being designed for at least five million switching cycles.

As in the PSM01 and PSM02 models, the core of the instrument is a flicker-free snap-action switch. It allows for high precision with a reproducibility of Âą2% of the full scale value in the measuring ranges 0.2-2 bar to 40-400 bar. WIKA delivers the three universally usable OEM pressure switches with a factory-set switch point on request.

WIKA Australia Contact info and more items like this at wf.net.au/V131

ETHERNET MODULAR I/O Turck has released the BL67 on-machine modular I/O system for industrial ethernet.

Designed to provide flexible communication capabilities, the modular I/O system elevates a variety of I/O signals to common industrial ethernet networks, including digital inputs, digital outputs, analog I/O and specialty I/O such as serial interfaces and RFID. Featuring the company’s multiprotocol technology, the system offers an easy-todeploy industrial ethernet solution, combining three ethernet protocols - EtherNet/IP, Modbus TCP and Profinet - in a single device, yet only allows one ethernet master to control the outputs while the input and diagnostic data is available to the other protocols. Designed to simplify industrial ethernet for distributed I/O, the system offers all the latest features, including quick-connect and DLR support for EtherNet/IP and fast start-up, LLDP, GSDML file configuration for Profinet and linear topology support for all three supported industrial ethernet protocols.

Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/V062

26 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

www.ProcessOnline.com.au

NEW PRODUCTS

WIDESCREEN MULTITOUCH MONITOR ENDOSCOPE

The FPM-7211W is a 21″ widescreen multitouch flat panel monitor spe-

The Fiberscope MTFS15-1000 is a high-quality, miniature,

cifically designed to provide easier

flexible fibre-optic endoscope that is designed for inspec-

operation and boost productivity in

tion and quality-assurance purposes. The fibrescope

manufacturing control environments,

is suitable for the inspection of miniature components

building automation and other HMI

and channels in the fields of microelectronics, precision

applications. The monitor features a widescreen ratio of

mechanics and research. It is available to rent.

16:9, providing 40% more screen area than traditional 4:3 aspect ratio dis-

The fibre-optic endoscope has a working length of 1000

plays. Resolution is full HD (1920 x 1080). Furthermore, with the addition of

mm and diameter of 1.5 mm, includes a light source

four-finger, multitouch capabilities it provides even greater control and viewing

and has a resolution of up to 30,000 image points. Op-

of the information displayed, such as zoom, slides, twist, etc.

erating temperature is from -20 to 60°C at atmospheric

Other features include RS232 and USB dual-touch interface, VGA and

pressure. Fibrescopes such as the MTFS15-1000 are

DVI-D dual video input port, 0-50°C operating temperature and an IP65 front

used for applications across many industries includ-

panel. The panel glass is hardened to 7H on the Mohs scale, which is the

ing machinery, boilers, automotive, aircraft, foundries,

same hardness as the mineral quartz.

chemical and construction. The fibrescope features a

The monitor can be mounted on panels, on walls or by a stand using the

low-friction vinyl protective tube and a focusable eye-

VESA hole behind the unit; providing a range of options for any industrial

piece, and is liquid tight.

environment.

TechRentals

Advantech Australia Pty Ltd

Contact info and more items like this at wf.net.au/V007

Contact info and more items like this at wf.net.au/V060

www.ProcessOnline.com.au

OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

NEW PRODUCTS

BLOW-THROUGH FEEDER FOR PNEUMATIC CONVEYING The BT Series blow-through feeder/airlock is designed to ensure optimal bulk density and throughput of hard-to-convey materials such as fine powders and flakes that, in high-pressure pneumatic conveying applications, can easily over-aerate and reduce material feed efficiency.

The feeder/airlock design decreases excess aeration of the material during conveying with an integrated vent port on the return side of the valve housing that automatically vents air leakage. The 8-vane rotary valve design is said to significantly reduce air leakage and maximise the flow path of air through the rotor pocket, improving material pocket release.

The minimal air leakage and resulting low, effective pressure drop of the series optimises material flow density, improves material conveying efficiency and reduces total compressed air consumption.

The strength of the valve housing provides optimal service in hightemperature applications and applications requiring pressure differentials up to 20 psig. The housings are also CNC machined to precise tolerances to ensure extended duty cycles by eliminating axial shaft movement, seal leakage and shortened bearing life. An outboard bearing design removes the bearings from the path of damaging and contaminating materials.

The series blow-through feeder/airlock housings are available in cast iron, 304 or 316 stainless steel, in either 20.32 or 25.40 cm round flange sizes. The series is available with a hard chrome housing interior and with adjustable rotor tips.

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

I/O EXPANSION FOR WIRELESS SYSTEM Updated multichannel I/O expansion modules for the Radioline wireless system from Phoenix Contact now make it possible to transfer up to eight digital signals. The wireless system is primarily used to communicate with remote devices in widely distributed systems. One feature is I/O mapping that allows Wind Energy

Photovoltaics

Communications

signals to be distributed within the system easily and without software.

Here, input signals receive I/O addresses by means of thumb wheels, with these addresses being mapped to corresponding output modules.

The wireless system has been upgraded with high-speed digital input and output modules that complement the existing wide-range inputs and relay outputs. The RAD-DI8-IFS input module processes eight digital input signals or two impulse signals between 0 and 100 Hz. The impulse inputs

Process Industry

Transportation

Security Systems

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

count events, eg, as a means of measuring flow rate. The 32-bit counters can be read out directly via a Modbus RTU controller. The corresponding RAD-DO8-IFS digital output module processes eight digital signals that are triggered via transistor outputs. Every Radioline station can be modularly expanded by up to 32 modules. The I/O expansion modules can be easily replaced when the system is running.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/U831

28 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW PRODUCTS

STAINLESS STEEL JUNCTION BOX the ability to consolidate up to eight individual, localised analog or

HAZARDOUS AREA CABLE GLANDS

discrete signals into a single device, this junction box streamlines

Cable specialist KabEx Aus-

connectivity requirements. For greater simplicity, the signals are then

tralia has released two OSCG

Turck has introduced a stainless steel process junction box. With

(E1WF and E1XF) ranges of

routed to a control unit through a single homerun cable.

In addition to simplifying connectivity, Turck stainless steel pro-

IECEx cable glands for use with steel wire armour or braided screened

cess junction boxes provide a robust connectivity

cables in hazardous areas including petrochemical, oil and gas, chemi-

solution in harsh environments such as oil and

cal, fertiliser, shipbuilding, paint and solvent, sugar, LNG, power and

gas exploration, offshore drilling platforms and

mining industries along with anywhere else where flammable atmosphere

pharmaceutical plants. The junction boxes

may exist. The E1WF and E1XF glands have double compression for

feature FM approval for Class 1, Division 2,

the outer/inner jacket of cable. Compression seals are made from

Groups A, B, C and D hazardous locations,

silicone instead of PVC and can be used for all types of armoured

and ingress protection of IP67 - including the

cables. Using compression seals made from silicone means that re-

junction boxes receptacles as long as the ports

terminating of cables will not compromise the seal, and the glands

are covered or connected. They have a cast

can be re-used. Complying to a range of international regulations,

316 stainless steel electropolished housing to

the E1WF and E1XF cable glands (E1WF is for steel wire armoured

ensure optimal performance in areas that present

cables and E1XF is for braided screen cables) are IECEx certified

severe environmental conditions including water,

for use in hazardous industrial areas within Australia as they are also

salt spray, gases and other corrosive materials.

triple certified Exd IIC, Exe II, ExtD A21 for Zones 1, 2, 21 and 22.

Turck stainless steel junction boxes utilise Turck

A full range of thread sizes is available up to M100 or 4″ NPT. Metric

minifast (7/8″) or eurofast (M12) port connectors

threads are supplied complete with locknut and sealing washer. The

and include a multifast (M23) homerun connector.

glands are available in nickel-plated brass or stainless steel.

Turck Australia Pty Ltd

Kabex Australia

Contact info and more items like this at wf.net.au/V115

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Easier connectivity. Easier control.

Introducing Magelis GTO, the innovative HMI with high-quality display and the widest choice of connection options.

Magelis GTO helps you build state-of-the-art machines and systems that improve operator efficiency while saving time, effort and money.

Plug and Play USB accessories

> Simplified design, configuration and mounting. > Wide range of USB plug and play accessories. > Unmatched screen clarity.

Open connectivity via serial link and TCP/IP ports

> Embedded Ethernet, serial and USB ports allow for easy connection to automation devices.

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> Remote viewing app Vijeo Design’Air for smartphone or tablet allows unlimited access to HMI applications.

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Access your application remotely with Vijeo Design’Air. Watch the FREE video to learn how.

Simply visit www.SEreply.com and enter key code 53400K www.schneider-electric.com.au | Call 1300 369 233 ©2013 Schneider Electric. All Rights Reserved. SEAU26884

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OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

NEW PRODUCTS

HYDRAULIC SUBMERSIBLE PUMPS When it comes to offshore production, submersible well pumps can be high maintenance and can significantly impact operational costs. The ClydeUnion Pumps hydraulic submersible pump (HSP) was developed by analysing the failure modes of traditional electric submersible pumps and designing them out, creating a pump with ultrahigh reliability and long service life. This pumping solution has typically around three times the life of an electric equivalent and offers increased availability providing for substantial reductions in offshore operational expenditure.

The removal of electrical power systems greatly reduces the opportunity for equipment failure. Longevity is enhanced through the use of the power fluid supplied from the surface, which provides life support to the critical balance and bearing systems.

Bearings and seals have also been eliminated, improving reliability and extending the useful working life of the pump.

The HSP operates at high speed and has a high energy density. It is therefore easier to install, and with increased robustness, reduces the risk of damage during its deployment.

The single shaft design of the combined pump and turbine enables the HSP to be supplied fully assembled and tested from the manufacturing facility.

The HSP is designed in the highest grade materials to resist wear and corrosion for the full life of a well. Its flexibility of operation means that it can handle 75% continuous gas content and 100% gas slugs, reducing the occurrence and risks of damage from gas lock.

SPX Flow Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/V064

30 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW PRODUCTS

NON-CONTACT INSPECTION OF EXTRUDER BORES The Micro-Epsilon idiamCONTROL extruder bore inspection system is designed to allow precise planning of the maintenance intervals or replacement intervals of individual extruder housing parts.

With compound extrusion lines, continuous wear signs occur in the bores caused by abrasive raw materials, temperature and pressure. The extruder bore inspection system detects the wear in the bores by noncontact internal inspection. The sensor unit - with integrated capacitive

PRODUCT-QUALITY VALIDATION SOFTWARE

sensors arranged opposite to each other - measures the diameter of the bore.

By turning the cross rollers by 40° clockwise or counterclockwise the bore can be measured in six tracks altogether. For exact positioning, the sensor is centred

on both

ATS International BV has announced

ends by spring-loaded rollers. Several metal pins prevent the measuring cylinder from turning.

the release of ATS CM4D v20. ATS

The controller unit, equipped with a touch screen, displays the measuring results graphically. The measuring

CM4D is a suite of product-quality

signal is shown as a diameter over the complete bore length and any tolerance deviations are immediately

validation applications designed to

displayed. The diameter values of several test cycles can be saved. By comparing the individual diameter values,

fill the gap between the virtual design

the extruder wear is calculated. For the data output the device is provided with a USB interface.

world of computer-aided design and the physical world of manufacturing.

It highlights differences between the

Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/V080

geometric design specification and the ‘as built’ data from a manufactured item. Within a large network, scrolling through a single list of hundreds of managed documents throughout multiple databases can be very tedious. With the advanced

Unbeatable Control,

Precision, and Flexibility

navigation of the Managed Document Selector, users can drill down using filters and sorting to find the managed document they want to open quickly and easily.

Due to the symmetry of the data from one side to the other, reports are often symmetrical as well. The existing report-building tool, ReportTweak, has been enhanced to allow users to easily create a report for one side of a part and then copy and mirror it for the other.

Enhancements to the array sheet allow users to temporarily rearrange the order of the sheets in the SheetSet or hide some of the sheets so that only the sheets that are needed at that moment are visible.

Graphical system design combines productive software and reconfigurable I/O (RIO)

Sometimes finding the needed

hardware to help engineers lower cost, increase productivity, and shorten design times.

data for a report can be difficult

This customizable, off-the-shelf platform, integrates motion, vision, and I/O with a single

when faced with multiple databases and many available routines. With

software development environment to build complex industrial systems faster.

the Find Feature capability, users can search for and find all points,

>> Accelerate your productivity at ni.com/industrial-control-platform

in all routines and databases that match a specified feature label string database.

Australia: 1800 300 800 New Zealand: 0800 553 322

ATS Applied Tech Systems

©2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 10367

without loading any data from the

Contact info and more items like this at wf.net.au/V045

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OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

© iStockphoto.com/Jovan Jaric

THE SIX GUIDELINES YOU NEED TO SPECIFY A BULK BAG FILLER Exponential growth in the use of bulk bags has spawned an entire manufacturing segment dedicated to producing specialised equipment that not only fills and discharges bulk bags, but offers various degrees of automation and integrates filling and unloading operations with upstream and downstream equipment.

A

s the number of bag filling equipment options increases, so should the ability of the specifier to evaluate standalone equipment and integrated systems against current and anticipated needs. This article addresses the ‘filler’ half of the bulk bag handling equation, offering the six most important parameters to consider when satisfying any individual bulk bag filling requirement with top efficiency and cost-effectiveness.

1. Anticipate maximum capacity The difficult but critical question: how many bulk bags will you need to fill per week during the useful life of your next bulk bag filler?

With few exceptions, buying a more costly filler with higher capacity than you now need will be less costly than replacing a filler you outgrow, unless that filler can be retrofitted with performance enhancements at a later date. Capacity requirements run the gamut, from one bag per week to 20 bags per hour. Where your volume falls should, in part, influence your decision to specify a manual, semiautomated or fully automated machine.

Generally speaking, the more manual the filling operation, the more output is subject to variation. When gauging the capacity and payback of manual equipment against automated equipment, you need to determine the average pace at which operators can attach, detach and cinch bag spouts, remove filled bags, load pallets and conduct all other filler-related operations. When estimating the time allocated to these manual functions, it is advisable to anticipate a pace that an operator can realistically maintain throughout an entire shift while avoiding fatigue or injury.

32 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

For the lowest volume applications, a basic manually operated filler will maximise your return on investment. Choose a filler design that affords unobstructed access to the bag spout and loops, facilitating rapid manual insertion and removal of bags. This class of filler is typically equipped as standard with fill head height adjustment via fork truck to accommodate all popular bag sizes, a feed chute vent port for dust-free air displacement during filling and an inflatable cuff to seal against the bag inlet spout and ensure it does not collapse on itself during filling.

The cost of a scale system can be avoided by placing the entire filler onto an all-purpose plant scale, providing the filler is properly equipped for in-plant mobility. Alternatively, if a forklift is unavailable to remove filled bags, configurations are available with a three-sided base that provides access from the open side using a pallet jack.

The time required to prepare empty bags for filling, and to remove filled bags from beneath the filler, can have as much or greater influence on maximum filling capacity than the rate at which material enters the bag. As such, adding a roller conveyor allows filled bags to be rolled out of the filling area for spout cinching and pallet/bag removal while another bag is being filled. Adding such a conveyor system, however, generally requires a filler with rear posts and a cantilevered fill head equipped with hooks that release bag loops automatically, so if higher capacity is in your future, a rear post configuration may be your best choice today.

Further increasing the capacity of systems equipped with roller conveyors to the next level generally entails adding an automated pallet dispenser which places pallets and slip sheets onto the roller

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Materials handling

conveyor upstream of the filling operation, further reducing the time required for each filling cycle by limiting manual operations within the filling station exclusively to loading an empty bag.

2. Evaluate safety against manual operations required at any given level of capacity With manual and semiautomated filling operations, the potential for worker fatigue and injury can increase according to required output per shift, relative to the type of bulk bag equipment specified.

Consider that the connection points of a conventional filler are often beyond the reach of most operators, even when short bags are being filled. But adding the height of a roller conveyor to the height of a bulk bag to the length of its bag loops puts the connection points for bulk bags of only 122 cm in height at approximately 213 cm above the floor!

This requires an operator to stand on a platform, a ladder or on the roller conveyor while straining to reach overhead spout connection points and inserting hands between temporarily disabled moving parts. Difficult-to-reach spout connection points can therefore compromise safety as well as capacity - two problems that can be solved with the addition of a fill head that lowers and pivots to the operator at floor level.

Repetitive manual tasks such as releasing bag hooks, placing pallets on a roller conveyor or actuating bulk material delivery also increase the potential for error and injury, justifying semi- or fully automated equipment for all but the lowest volume applications.

3. Ensure dust is contained Even the most rudimentary filler is likely to be equipped with an inflatable spout seal to hold the bag spout firmly in place during filling. However, not every fill head is vented to a dust collector to filter displaced air and dust, and to vacuum ambient dust in the operator’s vicinity during disconnection and cinching. It is therefore important to confirm that the filler you are considering is so equipped, particularly when contamination of the product or plant environment cannot be tolerated.

4. Determine your need for multifunction filling If your plant fills drums, boxes or other containers as well as bulk bags, multifunction fillers can boost production, undercut the cost of separate equipment and reduce the amount of floor space required.

Multifunction fillers can be switched from bulk-bag to drum-filling mode in seconds by positioning the swing-arm-mounted drum-filling chute under the fill head discharge port. The chute automatically rotates to deliver material to all four drums on a pallet. Similar adapters for boxes, totes or other containers are also available with varying levels of automation.

5. Match the feed source to your material and your filler Filling capacity, accuracy and efficiency are often limited by the ability of upstream equipment to feed material consistently and in sufficient volumes. High-capacity, semi- or fully automated fillers therefore require high-capacity feeding systems that are typically automated and feed material into the filler by gravity or by a metering device.

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The ability to gravity-feed material depends on whether a material storage vessel can be located above the filler and on the material’s flow characteristics. The more free-flowing it is, the more accurately its flow can be varied (down to dribble-feed rate) by a slide gate or other valve that must close the instant a precise target weight has entered the bag. Non-free-flowing titanium dioxide (TiO2), for example, may flow in a trickle and then in clumps, and it may bridge above the flow control valve, making it a poor candidate for gravity feeding.

For non-free-flowing materials, a metered feeding system is required to feed the filler accurately and consistently. Metering systems can include a flexible screw conveyor, screw feeder, rigid auger, drag disk, bucket elevator, rotary airlock valve or other device that does not rely on gravity alone to deliver material to the filler.

The selection of a metering system can hinge on the available space above the filler, since surge hoppers and filter receivers with rotary airlock valves may require more headroom than is available.

In these cases, the discharge housing of a flexible screw conveyor can often fit between the filler inlet and the ceiling joists, while eliminating the need for a flow-control valve.

For products that are easily aerated, pneumatic conveying systems should be avoided, since the conveying process can cause the material to require a much lengthier densification/deaeration cycle to achieve the desired fill weight and package stability.

If sufficient headroom exists above the filler, a surge capacity equivalent to the weight of a filled bag can be employed to reduce cycle times while maintaining accurate fill weights. This configuration allows bag changeover to occur while the subsequent batch is in the process of being weighed. When a pneumatic conveyor is used as the material delivery system, the filter-receiver can be sized to hold the weight of an entire bulk bag to apply this method.

For the same reason, a surge hopper above the filler can be considered when using mechanical metering devices to move material to the filler from both storage vessels and plant processes.

6. Comply with sanitary requirements While all fillers can be constructed of stainless steel with ground and polished welds, their designs can preclude sanitising according to government standards. If your application must meet sanitary requirements, your choices should be limited to designs that are accepted by the agencies to which you must comply, or to which you elect to comply for assurance that sanitary conditions can be maintained.

Conclusion With an almost unlimited combination of filler designs, features and upstream equipment from which to choose, specifiers have the ability to tailor bulk bag filling systems according to capacity requirements, expandability, safety concerns, plant hygiene considerations, ancillary filling needs, upstream equipment and sanitary standards.

While numerous available options can complicate the selection process, they can also yield a highly efficient and cost-effective solution to any given filling problem, providing that fundamental steps are taken to evaluate equipment against precise requirements.

Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/V254

OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

INDUSTRY-SPECIFIC PLM SOFTWARE Siemens has introduced a series of industry-specific PLM software offerings. The Industry Catalyst Series consists of a prepackaged combination of industry best-practice guides, templates and software aimed at accelerating PLM deployment and tailoring the system to the needs of specific industries.

The series is designed to increase a company’s overall return on its PLM investment, as well as the speed at which ROI is realised. The Industry Catalyst Series will work with one or more Siemens PLM Software offerings as well as in combination with third-party PLM solutions. Individual Industry Catalyst Series offerings will be announced over the next several months.

SAFETY PLC WITH ETHERNET/IP

Over the past several years, most organisations have come

The Pilz Safe Automation System PSS4000 now has the ability to commu-

to appreciate how PLM technology and processes can help

nicate with devices using EtherNet/IP. The latest addition of this protocol to

them increase productivity and efficiency, but have been slow

the existing wide variety of communication options makes the PSS4000 a

to implement a full scope PLM solution, or to adopt the latest

more flexible safety PLC. The merging of standard and safety is the focus

technology for their existing PLM system. This often stems

of the automation system PSS 4000, with easy-to-implement automation

from concern about costs and business disruptions associated

solutions possible for both standard and safety functionality.

with the need to customise standard PLM technology to their

The addition of the EtherNet/IP communication functionality is purely

specific needs. The Industry Catalyst Series minimises disrup-

a firmware upgrade option so existing PSS4000 PLC devices can be

tion by delivering an industry-tailored deployment more quickly.

updated with no need to replace any of the existing hardware. Users

Individual series offerings will be announced for a variety of

simply upgrade the existing PLC Head modules to V1.8 of the firmware and

industries including automotive, electronics, consumer products,

software. The PSS4000 PLC already communicates to external devices via

marine, energy, machinery, medical device and aerospace. In

Modbus TCP, and now the same device can communicate via EtherNet/IP.

addition to supporting multivendor PLM implementations, the

The company has also provided an application note to help with the

series offerings will work with all of Siemens’ enterprise-level

configuration of the EtherNet/IP connection which can be downloaded from

PLM software products including NX software, the Teamcenter

the their website at http://www.pilz.com/downloads/open/AN_PSS4000_

portfolio for digital life-cycle management, the Tecnomatix

ETH_IP_with_AB_1003034-EN-01.pdf.

portfolio for digital manufacturing and LMS software for test

For users who need to communicate with EtherCAT or CANopen

and mechatronic simulation.

systems, the gateway devices PSSnet GW1 MOD-EtherCAT and PSSnet

Siemens Ltd

GW1 MOD-CAN are now also available.

Contact info and more items like this at wf.net.au/V078

Pilz Australia Industrial Automation LP Contact info and more items like this at wf.net.au/U682

34 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW PRODUCTS

SOFTWARE-DESIGNED CONTROLLER The cRIO-9068 software-designed controller has been completely redesigned but maintains full NI LabVIEW and I/O compatibility with the CompactRIO platform. The controller integrates state-of-the-art technologies including the Xilinx Zynq-7020 All Programmable system on a chip (SoC), which combines a dual-core ARM Cortex-A9 processor and Xilinx 7 Series FPGA fabric.

Based on the LabVIEW reconfigurable I/O (RIO) architecture, the controller helps meet any demanding embedded control and monitoring task without wasting development time and cost.

The controller features four-times faster performance than previous generations, powered by a 667 MHz dual-core ARM Cortex-A9 processor and Xilinx Artix-7 FPGA; a Linux-based, real-time OS that provides greater flexibility for both LabVIEW Real-Time and C/C++ application developers; and an extended operating temperature range of -40 to 70째C. The controller, programmed with LabVIEW system design software, enables engineers and scientists to use a single, graphical development environment to take advantage of improved hardware performance. LabVIEW 2013 support for the NI Linux Real-Time OS gives developers access to a rich set of community-sourced libraries and applications to augment their control and monitoring systems. LabVIEW 2013 also offers expanded connectivity options including improved web service creation and secure, industry-standard WebDAV browser-based file management.

National Instruments Australia Contact info and more items like this at wf.net.au/U832

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OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

NEW PRODUCTS

INDUCTIVE ANGLE SENSORS Turck has announced a line of inductive angle sensors for rotary actuators. Operating with the inductive resonant circuit measuring principle, these inductive angle sensors deliver enhanced valve monitoring on rotary actuators. The sensors are designed with an open face design, providing analog or discrete outputs and flexible mounting options.

Turck inductive angle sensors are able to monitor three-way valves, while also detecting the valve position during cleaning cycles. Additionally, the sensors are capable of detecting the wear of seals, saving downtime from seals that are worn from switching cycles. For flexible operation, the sensors are available in two models, either with two programmable PNP switching outputs or with two scalable analog outputs of 0-10 V and 4-20 mA. These inductive angle sensors provide a freely adjustable range within 360°, eliminating the need for adjustment and readjustment of the actuating element.

Featuring a protection rating of IP67 and a rugged, compact housing design, the inductive angle sensors provide a wear-free sensing solution in harsh applications. The sensors provide optimal performance in temperatures ranging from -25 to 75°C, making them suitable for a wide range of applications including valve automation, steering position feedback and dancer arm control.

Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/V016

NEW ProBus RS 485 Modbus I/O Modules • Ideal for data acquisition and remote I/O. • Manufactured in Australia • Multi-channel analog and digital I/O modules.

• Modbus RTU communications.

• Ethernet Modbus TCP and Profibus gateways.

• Compact DIN-Rail packaging with integrated Bus connector.

Tel 02 9624 8376 Fax 02 9620 8709 Email proconel@proconel.com

www.proconel.com 36 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW

270x88mm HACH PACIFIC_DR 900:Layout

7/18/13

6:54 AM

PRODUCTS

FAST, SIMPLE AND FIELD READY. AUTOMATIC ARTICULATED PALLETISING ROBOT Designed to perform even complex palletising and de-palletising tasks reliably and efficiently, BEUMER’s robotpac is a space-saving, fully automatic articulated robot, for which the company has designed suitable gripping systems that can be changed flexibly for different types of packaged goods. An additional tool changer allows the fully automatic use of multiple gripping systems that can be operated from a single robot working area.

Grippers include: a fork gripper for palletising bagged goods and cardboard boxes; a finger gripper for palletising bagged goods; a parallel gripper for palletising cardboard boxes and other dimensionally stable containers with parallel side walls; and a suction gripper that handles all goods with suctionable surfaces.

The robot offers precision and availability, as well as gentle product handling. An ultrasonic system provides accurate measures of the stacking height, making it possible to calculate the exact placing position of the packaged goods and stack these precisely and carefully for optimal stack configuration.

Regulated by complex control mechanisms, the robot can stack packaged goods of variable dimen-

Introducing the NEW DR 900 Colorimeter.

sions on one pallet. Individual programs cover all packing patterns.

According to the company, the machine is easy to maintain and very quiet. Equipped with an additional drive axle and an integrated motor connected to the control system, the robot is freely movable

1300 887 735 www.hachpacific.com.au

on a guide rail. Consequently, it can be used in distribution centres for order-picking tasks.

The robotpac is claimed to be reliable even in dusty environments typical of packing plants and the building material industry.

BEUMER Group Australia Pty Ltd Contact info and more items like this at wf.net.au/V081

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OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

Page 1

NEW PRODUCTS

PROCESS PUMP RANGE Two Bran+Luebbe brand pumps, the Novados double-acting metering pump and Novaplex Vector process pump, are specifically designed with a reduced footprint and weight to accommodate offshore installation requirements. The Novados metering pump with double-acting head is suitable for applications such as methanol, polymer or glycol injection. This diaphragm pump has a single double-acting head which is said to provide the capacity of equivalent duplex pumps but with a much smaller footprint, lighter weight and lower initial capital cost for use in areas where space is a premium, such as offshore platforms or FPSOs. The use of the single double-acting head typically reduces weight and footprint by around 20% compared with two single-acting diaphragm pump heads.

The Novaplex Vector process pump is a triple diaphragm process pump that reduces the required footprint for installation by arranging the pump heads in three dimensions. Its design simplifies assembly and reduces the number of crankshaft bearings from six to two, increasing reliability and making maintenance easy. The model uses the Bran+Luebbe pump head design and is ATEX certified. Maintenance is further simplified as the unit only requires disassembly of the drive to gain access to the gears.

The Novados and Novaplex pumps can be equipped with the Novalink-CSM 2 continuous pump monitoring system. The software can be used as a stand-alone solution or incorporated into an asset management system to enable advance detection of possible pump failure. Its use can help to optimise maintenance schedules, maximise uptime and protect production capacity.

SPX Flow Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/V063

WIRELESS DATA LOGGERS The HD35 series of wireless data loggers from Delta Ohm are available for a variety of parameters including: temperature; relative humidity; atmospheric and differential pressure; wind speed and direction; illuminance and UV radiance; solar radiation; CO; CO2; rain; and acceleration.

A version is also available for standard process sensors including PT100 and thermocouple temperature sensors, 4-20 mA and voltage signals. All remote units have an internal memory of up to 74,000 readings and a secure robust wireless system with RF interference checking and automatic channel selection within the wireless operating band to ensure error-free transmission. Optional repeaters are available to extend the wireless range.

Data stored in the loggers is retained until the memory is full, even after it has been sent to the base unit. The logger can then be programmed to stop logging or overwrite the older data. IP67-rated outdoor versions of all data logger transmitters are also available.

Base units can handle up to 254 data loggers and versions are available with a USB PC interface and an integral GSM module (for SMS and email messaging), RS485 and Modbus outputs. Additionally, a wireless alarm module is available controlled by the base station with two relay outputs for controlling alarm systems, etc. Other features include an LCD option on all logger units, a lockable flange mount, user-friendly graphical software with many features including information of battery level, signal level and connection status of each logger.

W&B Instruments Pty Ltd Contact info and more items like this at wf.net.au/V043

38 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW PRODUCTS

BULK BAG FILLING SYSTEMS National Bulk Equipment (NBE) bulk bag filling systems are engineered, fabricated and constructed to speed inspections, simplify integration and ensure qualification for start-up into food processing and packaging operations. The systems are 3-A, USDA, FDA and BISSC compliant. These sanitary bulk bag filler systems also support process practice protocols where 3-A Accepted Practices or other cGMPs are necessary. The systems include features such as: 32 Ra surface finishes to simplify cleaning; tool-less, demountable assemblies to speed inspection; 3-A compliant components to aid in sanitary standards conformance; HEPA air filtration for sanitary bag inflation; and a structural framework leak test system to facilitate clean-in-place (CIP) procedures. These sanitary bulk bag fillers also offer NTEP-certified weigh devices to assure certified weight accuracy to Âą.01%, to a 2000 kg bag weight. The integrated automation of NBE sanitary bulk bag fillers standardises controls programming and expands controls functionality to include legacy systems. System-wide automation of process operations, diagnostics and reporting are controlled through a single HMI. NBE integrated automation is claimed to improve equipment performance, optimise throughput and increase operator safety.

National Bulk Equipment Contact info and more items like this at wf.net.au/V040

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OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 39

RS485 DATA ACQUISITION A NEW CHAPTER Steve Huang and Wayne Chen, Moxa Inc RS485 and ethernet are two commonly adopted communication interfaces used in data acquisition and control systems. Ethernet I/O devices are generally considered more sophisticated, RS485 I/O devices may be sufficient for budget-conscious system integrators. Nonetheless, there are still ways device manufacturers can improve on the lasting legacy of RS485 data acquisition devices.

T

he biggest drawback of using RS485 remote I/O devices instead of alternative technologies, such as ethernet I/O devices, is probably the communication speed. For example, RS485 networks only offer data transmission speeds from 1.2 to 115.2 Kbps whereas ethernet networks can transmit data at rates of 10/100 Mbps.

Despite their physical limitations and maintenance difficulties, RS485-based remote I/O devices remain some of the most commonly used data acquisition devices in both commercial and industrial applications today, even with so many new data acquisition technologies becoming available.

RS485 limitations A number of practical limitations and time-consuming maintenance problems persist with RS485 devices. As technology continues to advance and industrial data acquisition devices become more and more sophisticated, system integrators tasked with choosing between RS485 and ethernet I/O devices for their data acquisition networks often cite the following issues for turning away from RS485.

40 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

Physical limitations Although RS485 data acquisition devices can be used to build multipoint communications networks, the standard architecture is limited to 32 drivers and up to 32 receivers on a single (2-wire) bus. Furthermore, RS485 data acquisition devices have no intrinsic method of avoiding data packet collisions. As a result, only one node in the entire network can transmit data to the bus at any given time, and all other nodes must wait in receiving status. If two or more nodes transmit data to the bus at the same time, all transmissions will fail.

Difficult troubleshooting The process of configuring or updating RS485 data acquisition devices can be excruciatingly time-consuming because engineers must adjust each communication parameter one by one. Replacing RS485 devices or expanding an existing RS485 network usually requires an engineer to bring a personal computer to various field sites to configure parameters or upgrade firmware for each field device. In a network comprising hundreds of devices spaced up to 1.2 km apart from each other, one can only imagine the hassle

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Data acquisition

limited resources in training skilled maintenance professionals or building an expensive ethernet network. However, it is important to note that such cases are not mission-critical, which explains the low priority placed on preventing data loss, establishing network redundancy to ensure continuous connection or reducing system downtime.

There may be times when a cheap and simple RS485 data acquisition device is enough, but as the world becomes smarter and enterprises become more sophisticated, so must network devices used in modern data acquisition systems. As a result, savvy system integrators are not only on the lookout for easy-to-use and cost-effective solutions, but also network devices that are more dependable, easier to deploy and maintain, and reliable enough for backup or redundancy.

Some new ideas for RS485 data acquisition A smarter RS485 data acquisition device should not only be equipped with all the basic benefits of RS485 communication, but also address the standard’s traditional limitations. Although not much can be done about the standard’s physical limitations, innovative device manufacturers can still find ways to improve on the tried and true foundation of RS485 serial communications. © iStockphoto.com/TimTheToolman

Easier maintenance through software configuration

and cost of hiring an engineer to haul a personal computer from one field device to the next.

Serial communication is often sufficient Despite the traditional shortcomings discussed above, many system integrators continue to choose RS485 I/O devices over faster ethernet-based alternatives due to the former’s simple design, ease of control, and low cost of deployment and maintenance. In addition, RS485 can establish peer-to-peer communications between devices up to 1220 m apart before repeaters are needed, whereas ethernet switches and I/O devices are limited to only 100 m before repeaters are required to re-amplify communication signals.

Compared to ethernet I/O devices, RS485 I/O devices are still relatively inexpensive and thus attractive options for organisations that lack economies of scale and cannot afford the more expensive ethernet option. Many small and medium-sized enterprises, especially those in developing countries, opt for RS485 remote I/O devices because the low deployment and material costs make replacing broken machines an economical alternative to investing

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Instead of manually turning hundreds of dials and switches across a large field site, using software to configure all the RS485 devices on the network would greatly reduce deployment and maintenance effort. This software should enable quick access to all the RS485 data acquisition devices’ status information and settings in a userfriendly graphic interface. In addition, the software configuration tool should also provide an easy method for updating firmware remotely for all the data acquisition devices on the RS485 network.

The ideal software configuration tool would also allow users to set up their RS485 data acquisition device’s communication parameters from a remote location. So, instead of turning hundreds of dials to configure COM ports and device IDs during initial set-up for all the data acquisition devices on the same RS485 network, simply configure and duplicate the baud rate and mode for each network device through the graphical user interface. Converting manual hardware configuration to user-friendly software configuration will not only ease the effort of maintenance engineers, but also simplify the process of upgrading traditional device configurations and firmware.

Deployment and maintenance by USB Although RS485 is a relatively simple technology, RS485 networks are not necessarily easy to maintain. In particular, companies are still required to train a specialised engineer who must carry a personal computer to the field site when remote access is insufficient. A simpler way to troubleshoot and repair field devices when field visits are necessary would not only allow system integrators to reduce labour costs, but also alleviate the maintenance effort of field engineers.

OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

Data acquisition

Figure 1: A user-friendly software interface can make configuring hundreds of network devices easy and less time-consuming.

Figure 2: Dual RS485 ports open up more network topologies for backup and redundancy.

One solution is to add a USB port to the serial data acquisition device. This would serve as an alternative method for upgrading and configuring RS485 remote I/O communication devices and firmware if remote maintenance was not feasible. All the engineer needs to do is upload the configurations onto a USB drive, bring the USB drive to the field site, plug it into the field device’s USB port and all the configurations and firmware updates will upload to the field device automatically.

case the primary system goes down. Although dual RS485 ports are nothing new, an additional RS485 port enables maintenance engineers to test or repair an I/O device more quickly when one of the RS485 ports is damaged. So even though RS485 remote I/O devices are already considered a low-cost technology, the addition of dual RS485 ports can help system integrators save even more down the road without compromising on reliability.

Redundant RS485 ports

RS485 data acquisition - the next chapter

Even though packet loss and transmission failures are common issues encountered by RS485 networks, these problems can be easily prevented. System integrators for mission-critical applications generally deploy some type of backup system or redundant network to ensure that devices operate continuously without failing. If an RS485 data acquisition device were equipped with dual RS485 ports, system integrators could easily set up dual wiring or dual computer redundancy to back up their network.

For wiring redundancy, when the central computer detects that one of the RS485 connections is not responding, it can quickly switch over to the other RS485 line to guarantee continuous communication between the field sensor and the central computer.

Alternatively, the additional RS485 connection on the I/O device could connect field devices to a secondary computer on a local network to provide system operators with a secure backup in

Thanks to their affordability and simplicity, modern RS485 serial devices are here to stay because they not only provide all the basic benefits of RS485 communication, but also address some of the common limitations of traditional RS485 remote I/O devices. In particular, time-consuming maintenance can be greatly reduced by introducing user-friendly improvements like software configuration, uploading configurations or firmware via USB, dual RS485 ports and built-in repeaters. These are all practical solutions that can help enterprises around the world integrate RS485 I/O devices into an existing network, ease maintenance effort, reduce costs and generate business growth at the same time.

MOXA Inc Contact info and more items like this at wf.net.au/V118

EXPANDED HYGIENIC VALVE RANGE In the production of foods and beverages, and also of pharmaceuticals and cosmetics, the requirements for hygiene and process reliability are especially stringent. The fittings used in these applications have to be able to be cleaned quickly, easily and, above all, thoroughly.

BĂźrkert is now expanding the line of valves in the Element design and is increasing the maximum available orifice size of the seat valve type 2100 (angle seat on/off), 2101 (globe valve on/off), the control seat valve type 2300 (angle seat) and 2301 (globe) from 15 to 100 mm.

This significantly expands the area of application for these valve types, enabling their use at higher medium pressures on pipelines with an orifice opening up to DN 100. The expanded area of application now makes it possible to equip many systems entirely with fittings from the Element series. The advantages of the modular Element platform can be used comprehensively. The valves and sensors control fluids, steam, caustic solutions and chemicals, as well as abrasive or high-purity substances in many applications and process environments. The stainless steel valves are rugged, hygienic and easy to use. The special drive design facilitates integration of automation units at all levels of the modular valve system, from the position transmitter to the electropneumatic positioner or process controller. This concept allows complete decentralised automation of even complex systems with minimal expense for cables and hoses.

Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/V134

42 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW PRODUCTS

BULK BAG FILLING PROCESS SYSTEM NBE has introduced a bulk bag filling process system that includes an automated pallet introduction, automated metering of material supply, NTEP-certified precision bag weighing and automated, filled-bag accumulation conveyors. It is designed to enable a single operator to process up to twenty 2000 kg bulk bags per hour or 40,823 kg of dry bulk material per hour.

NBE integrated automation uses a single, menu-driven HMI to centralise system-wide operations - including legacy, upstream material supply equipment. NBE integrated automation directs all equipment controls, communication, sensing, monitoring and data reporting using UL listed panels built by the company. Process line optimisation begins immediately upon the introduction and staging of the first pallet. The cantilevered fill head/bag hanger carriage uses pneumatic actions to bring the fill head and rear bag hooks to well within the operator’s reach; no need for the operator to step or lean into the equipment. The 8 gpm hydraulic carriage easily and safely lifts bag capacities up to 2000 kg, far exceeding the lift speed and capacity of ball screw designs. The physical ergonomic design maintains optimal operator posture for safe and efficient operation. The NTEP-certified weigh systems provide valid, accurate and repeatable weighing of the bulk bags to an accuracy of ±0.01% of the 2000 kg bag weight. The NTEP-certified precision weighing improves total process efficiency by eliminating reworking of over- and under-filled bags and reducing material loss. The bag densification platform uses 3 g high-speed, low-intensity vibration to settle material in the bag to a dense, stable and safe load.

National Bulk Equipment Contact info and more items like this at wf.net.au/V035

RUGGED PLC ABB’s ‘extreme conditions’ AC500-XC PLC is protected

HD35 SERIES WIRELESS DATA LOGGERS

against a wide variety of threats including high and low temperatures, high humidity, low air pressure, salt mist and hazardous gases, and vibration and

■ Versions for wide range of parameters Including: ˚C/Rh/CO/CO2/Lux/UV. ■ Error free transmission with automatic channel selection & data security.

■ Remote units with up to 74,000 reading Integral memory and display options.

shock. This typically reduces system building costs by eliminating the need for sophisticated protective enclosures with special seals, HVAC, shock absorbers or EMC protection.

The AC500-XC PLC is a ruggedised variant of ABB’s modular AC500 PLC. Almost all of the modules in the AC500 range are available in XC (eXtreme Conditions) variants, providing users with a modular control platform offering greater flexibility and scalability.

AC500-XC PLCs also run exactly the same program code as the AC500, simplifying development for large systems that require control systems for both standard and extreme conditions.

Embedded environmental protection opens up extensive applications potential for the ABB AC500-XC. Extended temperature operation allows

■ Base units with GSM messaging, alarms,Wi-Fi and repeater options.

the PLCs to operate in temperatures from -30 to +70°C, with reliable

■ Economically priced, fast delivery & 2 year warranty and this is just the beginning...

conformally coated to protect against high humidity levels. The PLC has

system start-ups in temperatures as low as -40°C. Circuit boards are extended immunity against salt mist and atmospheres with corrosive gases such as H2S, SO2, Cl2 and NO2. High levels of vibration and shock can be tolerated, with accelerations up to 4g from random vibrations up to 500 Hz, or 2g from sinusoidal vibration. The PLC is capable of operating at altitudes up to 4000 m. It also offers extended EMC protection against voltage surges and fast transients, as well as electrostatic discharge.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/V015

44 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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NEW PRODUCTS

WLAN COMPONENTS The latest WLAN components from the Siemens Industry Automation division offer a data rate of up to 450 Mbps, allowing larger amounts of data to be transferred securely and quickly - making them suitable for applications with video, visualisation or voice data.

With the use of multiple input multiple output (MIMO) technology and three antennas per wireless interface, these devices can achieve long ranges and a highly robust wireless communication. As a result, these components are suitable for both wireless communication in an automation environment as well as industry areas such as logistics, airports, roads and underground railway tunnels or crane systems. Typical applications for wireless data transmission via IWLAN are the monitoring of safety-critical areas for the protection of persons or the monitoring of processing and storage procedures in high-bay storage systems.

The access points are available in three versions, suitable for outdoor use (SCALANCE W786), indoor use (SCALANCE W788) and stationary or mobile devices with ethernet capability (SCALANCE W748).

In addition, the IWLAN controller SCALANCE WLC711 allows central configuration and monitoring of up to 32 access points and client modules. A controller-based wireless network solution reduces effort and costs during commissioning and operation of larger IWLAN installations. With parallel operation of two SCALANCE WLC711 IWLAN controllers, the availability of the communication network can be increased.

Siemens Ltd Contact info and more items like this at wf.net.au/V116

46 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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CASE STUDY

Air knives ideal for perfect tiles For success in making its high-quality decorative tiles, Southern Cross Ceramics requires a dry and contaminant-free tile surface to allow the screen printing process to be successful.

Since 1987, Southern Cross Ceramics has been using sophisticated technologies to manufacture tiles in accordance with international standards and has a world-class colour laboratory to allow it to create diverse designs and colours.

Screen printing is one of the most versatile methods used for printing glazing materials onto ceramic tiles - the technology allows the printing of different decorative materials onto complex surfaces, penetrating into the uneven printing surface. The need for a dry and contaminant-free tile is due to the fact that the presence of the tile chips or any excess moisture on the tile during screen printing may lead to creation of scrap on the surface of a tile.

In order to solve the problem, S o u t h e r n C ro ss C e ra m i c s Plant Engineer Peter Lawson considered using air knives. He had looked into the use of air knives for a range of applications before, including removing moisture from difficult surfaces and drying of crates for labelling.

Peter and Braydon Cocks of Hurll Nu-Way were looking for the most cost-efficient solution and discussed two options, using a blowing system or using the current compressed air capacity.

A blower system is considered to be more energy efficient and quiet, while compressed air is expensive to generate. However,

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the existing compressor had some leftover capacity in the current system, which allowed solving the problem with minor investments.

They had to find an efficient air knife capable of delivering the capacity needed. Braydon offered the high-performance, lownoise and low air consumption compressed air knife Neublade, manufactured in the UK. The low dBa reading of the air knives during their operation was of high importance due to OHS regulations. The operators have to be safe in the area where they work.

Installing the air knife was easy due to the fact that the model has many thought-out mounting options, and the results were seen immediately - consistent air stream across the tile, very efficient and solving the problem straight away.

Hurll Nu-Way has been a long-term equipment supplier for the company, providing the tile manufacturer with infrared process heaters for heating and drying the ceramic paint.

Its sales engineers and product specialists are highly professional, knowledgeable and helpful. Among other products, HNW can supply to the ceramics, tile and printing industry, there are gas burners, centrifugal blowers, high-velocity fans and infrared heaters used to heat the warehouses.

Hurll Nu-Way Pty Ltd Contact info and more items like this at wf.net.au/V046

OCTOBER 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 47

NEW PRODUCTS

FLEXIBLE SHAFT COUPLINGS Zero-Max’s Double Flex A1C high-

WIRELESS PUSH-BUTTON

performance CD couplings provide

The Banner Engineering SureCross wireless

higher misalignment capacity than

Q45 push-button with confirmation light

the Single Flex model. The coupling

includes bidirectional communication

provides precise positioning under

that permits operators to send a digital

high-speed reversing loads without fatigue for

signal with the push of a button, and to

reliable 24/7 operation. The CD coupling design has high

receive confirmation the signal has been

torsional stiffness, yet allows for misalignment in high-stress applications.

received. The self-contained wireless

In addition, the zero-backlash couplings work well with reversing loads and

radio network can operate on a 2-point,

provide smooth operation at high speeds. The design is compact to allow

6-point or multipoint system; its noise im-

for a smaller assembly.

munity eliminates cross-talk, while network

The clamp-style hub design provides reliable shaft engagement. Shafts

IDs allow multiple systems to coexist. The

have increased clamping strength, eliminating the need for keyways for a

device’s frequency-hopping signal ensures

cleaner, better-balanced design. All CD A1C components are made of pre-

secure data transfer. The push-button has a line-

mium materials. Precision-machined hubs are made from ISO grade 7075-T6

of-site range of up to 900 m - enough to easily

aluminium; hubs are black anodised to a MIL-A-8625 Type 2, Class 2 finish;

cover very large factories. The push-button can run

and recessed fasteners are ISO 4762 grade 12.9 socket head cap screws.

for up to five years on two AA lithium batteries, or

The composite disc is made of high-precision composite material that is

it can be powered by a local 10-30 V power sup-

manufactured to strict aerospace and Six Sigma practices. The material is

ply. The battery option is suitable for applications that require

said to have excellent chemical and moisture resistance. The A1C couplings

the push-button to be mobile or far from a local power source.

are precise, robust and available in six sizes. Peak torque capacities range

The push-button model is part of the company’s SureCross

from 40 to 564 Nm with speed ratings from 6700 to 15,000 rpm depending

DX80 wireless I/O system.

on the model.

Micromax Pty Ltd

Naismith Engineering & Manufacturing Co Pty Ltd

Contact info and more items like this at wf.net.au/V061

Contact info and more items like this at wf.net.au/V076

PRESSURE | TEMPERATURE | LEVEL | FLOW ELEMENTS | CALIBRATION INSTRUMENTS

If your instrumentation requirements are for any of the above, speak to us and benefit from a manufacturer with experience and international recognition.

We value your enquiries.

Phone: 02 8845 5222 Email: sales@wika.com.au

Fax: 02 9684 4767 Web: www.wika.com.au

WIKA group of companies include:

48 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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CHOOSING COGENERATION FOR ENERGY EFFICIENCY IN FOOD AND BEVERAGE

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

E

nergy-efficient manufacturing is critical as changing economic and environmental demands force manufacturers and plant developers to consider alternative forms of production. Cogeneration is an increasingly important energy option to consider when designing food and beverage manufacturing facilities, providing an attractive long-term management choice.

Typical centralised electricity generation plants are high energy generators but produce a lot of heat and expend energy to get rid of it. This heat is not used, making production inefficient. There is also a high degree of energy loss in the transmission lines to the plant. Cogeneration basically takes the generation of electricity to the site and allows heat to be used rather than expending energy getting rid of it. This heat would have previously been paid for in the plant’s boilers, but with cogeneration done correctly it comes at a reduced cost.

In food and beverage processing, trigeneration is also useful as it uses heat to drive refrigeration - making it well placed in the efficiency cycle. Trigeneration using absorption chillers needs low-grade heat and utilises what is left over after steam and hot water production. This option is energy efficient and good for the environment - using less energy from traditional fuels means fewer greenhouse gas emissions.

Cogeneration’s biggest drawback is that energy supply from centralised power plants is cheap, and to make cogeneration economically viable requires efficient design, efficient usage and the right energy prices.

To design an efficient plant, the first element is making use of all of the incoming energy.

For example, a milk powder plant may have little need for refrigeration, while a cheese plant is expected to require a high level of temperature control and refrigeration usage. Conversely, the powder plant will have higher relative heat demand. If refrigeration is removed, each may use about the same amount of electricity rela-

tive to milk inputs. Balance is extremely important, and the developer must ensure the cogeneration plant considered is the right match to achieve balance.

A large range of plant sizes exists, from the engines and turbines generating the electricity through to heat recovery steam generators, heat exchangers and absorption chillers. Matching a plant to these varying energy demands is a relatively simple yet detailed process, with the primary aim being not to waste anything.

It does not always work, however - if a plant is too small it is difficult to achieve economies of scale through cogeneration or trigeneration. An unfortunate reality, but possibly a rule of thumb, is that plants under 1 MW will struggle, as larger machines perform more economically.

Added realities are that the solution needs to cater for usage peaks and technical requirements around the way plants operate - they perform better, cleaner and with less maintenance if run consistently. These details need to be modelled and optimised to find the most appropriate solution for the particular application. It is clear, in this era of rising energy costs, that there are real gains to be made, both in economics and the environment, by an effective cogeneration or trigeneration project.

Publisher Geoff Hird Art Director/Production Manager 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.

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Dr Steve Edwards, Principal Consultant Energy and Water, pitt&sherry, has 25 years’ experience as a scientist with a background in organic and natural products chemistry, and in aquaculture. Since joining pitt&sherry in 2007, Steve has gained extensive experience in process optimisation and process modelling, with a particular focus on carbon accounting and energy and water efficiency.

50 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2013

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