What’s New in Process Technology Feb 2014

ON THE COVER

0214 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

Hawk Measurement Systems (HAWK) is a world leader in level, positioning and flow measurement technology. HAWK uses

CONTENTS

acoustic wave technology for its non-intrusive, Sultan continuous level transmitter range.

6

Applications include primary crusher surge bins, secondary and tertiary crushers, pro-

Part 1

cess slurry tanks, stockpile level control, truck detection, shuttle conveyor positioning and anti-collision controls.

The major advantages that acoustic wave

I mproving alarm management with ISA-18.2

11

New products

14

Hot products online

34

conomical vacuum supply in meat E processing plants

technology brings to applications in the mining, power, wastewater, chemical, oil and gas industries are: • The automatic cleaning of condensation

Centralised pumping provides potential savings when generating vacuums

and buildup off the face of the measuring diaphragm (something that radar technologies do not offer).

• Two-wire loop powered transmitters, with the

42

As I see it Sustainability - the key to success

same power as mains powered acoustic transmitters, with a range of up to 100 m.

• R emote transmitters (for the two-wire series) that can be run up to 600 m from the transducer.

Acoustic wave technologies distinguish themselves from traditional ultrasonic and radar level systems by combining low frequency, high power and adaptive gain technology.

In this way, users can measure level even in the most difficult applications, such as primary crusher surge bins, and process sumps that suffer from condensation, froth and foam. These applications have always been problematic on mine sites and by careful selection of transducer frequencies and housing materials, HAWK can offer process application guarantees.

NOW in DIGITAL! Hawk Measurement Systems Pty Ltd www.hawkmeasure.com

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

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IMPROVING ALARM MANAGEMENT WITH ISA-18.2 PART 1

Poor alarm management is one of the leading causes of unplanned downtime and has been a major contributor to some of the worst industrial accidents on record. Changing the practices and procedures used in the plant has become easier and more important with the release of the ISA-18.2 standard, which provides a blueprint for creating a safer and more productive plant.

6 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

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I

n difficult economic times, focusing on operational excellence is a key to short-term survival and to future growth. However, poor alarm management is a major barrier to reaching operational excellence, and has been known to result in unplanned downtime, which can cost $10k/h to $1m/h for facilities that run 24x7. It also impacts the safety of a plant and its personnel, having played a major part in some of the major incidents of the last decade that resulted in significant cost in the form of injury, loss of life, equipment and property damages, fines and damage to company reputations.

In June of 2009 the standard ANSI/ ISA-18.2-2009, ‘Management of Alarm Systems for the Process Industries’, was released. In this two-part article we will review ISA-18.2 and describes how it impacts end users, suppliers, integrators and consultants.

Introducing the ISA-18.2 standard ISA-18.2 provides a framework for the successful design, implementation, operation and management of alarm systems in a process plant. It builds on the work of other standards and guidelines such as EEMUA 191, NAMUR NA 102, and ASM (the Abnormal Situation Management Consortium). Alarm management is not a ‘do once’ activity - rather it is a process that requires continual attention.

Consequently, the basis of the standard is to follow a life-cycle approach as shown in Figure 1.

The connection between poor alarm management and process safety accidents was one of the motivations for the development of ISA-18.2. Both OSHA and the HSE have identified the need for improved industry practices to prevent these incidents. Consequently, ISA-18.2 is expected to be “recognised and generally accepted good engineering practice” (RAGAGEP) by both insurance companies and regulatory agencies.

As such, it becomes the expected minimum practice.

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Common alarm management problems The ISA-18.2 standard is quite specific in defining an alarm: Alarm: An audible and/or visible means of indicating to the operator an equipment malfunction, process deviation, or abnormal condition requiring a response.

This clear definition of an alarm is helpful in understanding an alarm’s intended purpose and how misapplication can lead to problems. One of the most important principles of alarm management is that an alarm requires a response. This means if the operator does not need to respond to an alarm (because unacceptable consequences do not occur), then that particular alarm is probably unnecessary. Following this cardinal rule will help eliminate many potential alarm management issues.

The recommendations in the standard provide the blueprint for eliminating and preventing the most common alarm management problems, such as those shown in Table 1.

Following the ISA-18.2 standard Philosophy (Phase A) The first phase of the alarm management life cycle focuses on the development of an alarm philosophy document. This document establishes the standards for how your company or site will address all aspects of alarm management - including design, operations and maintenance. It should contain the rules for classifying and prioritising alarms, for using colour to indicate an alarm in the HMI, and for managing changes to the configuration. It should also establish key performance benchmarks, such as the acceptable alarm load for the operator (average number of alarms per hour). For new plants, the alarm philosophy should be fully defined and approved before commissioning. Roles and responsibilities for those involved in the management of alarms should also be clearly defined.

FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 7

Alarm management

Alarm management problem

Cause(s)

Alarms are generated which are ignored by the operator.

Nuisance alarms (chattering alarms and fleeting alarms), faulty hardware, redundant alarms, cascading alarms, incorrect alarm settings, alarms have not been rationalised.

When alarms occur, operators do not know how to respond.

Lack of training and insufficient alarm-response procedures.

Minor plant upsets generate a large number of alarms.

Average alarm load is too high. Redundant alarms, cascading alarms, alarms have not been rationalised.

The alarm display is full of alarms, even when there is nothing wrong.

Nuisance alarms (chattering alarms and fleeting alarms), faulty hardware, redundant alarms, cascading alarms, incorrect alarm settings, alarms have not been rationalised.

Some alarms are present on the alarm display continuously for long periods of time (>24 hours).

Corrective action is ineffective, equipment is broken or out of service, change in plant conditions.

During an upset, operators are flooded with so many alarms that they do not know which ones are the most important

Incorrect prioritisation of alarms. Not using advanced alarm techniques (eg, state-based alarming).

Alarm settings are changed from one operator to the next.

Lack of management of change procedures.

Table 1: Common alarm management problems that can be addressed by following the alarm management life cycle of ISA-18.2.

Figure 1: The alarm management life cycle 1.

Identification and rationalisation (Phases B and C) In the second part of the alarm management life cycle, potential alarms are identified.

There are many different sources for identifying potential alarms including P&IDs, operating procedure reviews, process hazards analysis (PHA), HAZOPs, incident investigations and quality reviews.

Next, these candidate alarms are rationalised, which means each one is evaluated with a critical eye to justify that it meets the requirements of being an alarm.

• Does it indicate an abnormal condition?

• Does it require an operator action?

• Is it unique (or are there other alarms that indicate the same condition)?

Alarms that pass this screening are further analysed to define their attributes

(such as limit, priority, classification and type). Alarm priority should be set based on the severity of the consequences and the time to respond. Classification identifies groups of alarms with similar characteristics (eg, environmental or safety) and common requirements for training, testing, documentation or data retention. Safety alarms coming from a safety instrumented system (SIS) are typically classified as ‘highly managed alarms’. These alarms should receive special treatment particularly when it comes to viewing their status in the HMI. Alarm attributes (settings) are documented in a master alarm database, which also records important details discussed during rationalisation - the cause, consequence, recommended operator response and the time to respond for each alarm. This information is used during many phases of the life cycle. For example, many plant operations and engineering teams are afraid to eliminate an existing alarm because it was “obviously put there for a reason”.

With the master alarm database, one can look back years afterward and see why a specific alarm was created (and evaluate whether it should remain).

Documentation about an alarm’s cause and consequence can be invaluable to the operator who must diagnose the problem and determine the best response. The system should allow the alarm rationalisation information to be entered directly into the configuration so that it is part of

8 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

the control system database and so that it can be made available to the operator online through the HMI. One of the major benefits of conducting a rationalisation is determining the minimum set of alarm points that are needed to keep the process safe and under control. Too many projects follow an approach where the practitioner enables all of the alarms that are provided by the DCS, whether they are needed or not, and sets them to default limits of 10, 20, 80 and 90% of range. A typical analog indicator can have six or more different alarms configured (eg, high-high, high, low, low-low, bad quality, rate-of-change, etc), making it easy to end up with significantly more alarm points than are needed. To prevent the creation of nuisance alarms and alarm overload conditions, it is important to enable only those alarms that are called for after completing a rationalisation. Thus an analog indicator, for example, may have only a single alarm condition enabled (such as a high-level alarm).

Detailed design (Phase D) Poor design and configuration practices are a leading cause of alarm management issues. Following the recommendations in the standard can go a long way to eliminating the issues. In many control rooms, more than 50% of standing alarms are for motors (pumps, fans, etc) that are not running.

During the detailed design phase, the information contained in the master alarm

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OU CAN DO THA

Alarm management

Signal type

Deadband (% of range)

Delay time (on/off)

Flow rate

5%

15 seconds

Level

5%

60 seconds

Pressure

2%

15 seconds

Temperature

1%

60 seconds

Table 2: Recommended starting points for alarm deadbands and delay timers 1. Note: Proper engineering judgement should be used when setting deadbands and delay times.

Alarm State

Audible indication

Visual indications Colour

Symbol

Blinking

Normal

No

No

No

No

Unacknowledged (new) alarm

Yes

Yes

Yes

Yes

Acknowledged alarm

No

Yes

Yes

No

Return to normal state indication

No

Optional

Optional

Optional

Unacknowledged latched alarm

Yes

Yes

Yes

Yes

Acknowledged latched alarm

No

Yes

Yes

No

Shelved alarm

No

Optional

Optional

No

Designed suppression alarm

No

Optional

Optional

No

Out of service alarm

No

Optional

Optional

No

Table 3: ISA-18.2 recommended alarm state indications 1.

database (such as alarm limit and priority) is used to configure the system. Alarm settings should be copied and pasted or imported from the master alarm database directly into the control system configuration to prevent configuration errors. Spreadsheet-style engineering tools can help speed the process, especially if they allow editing attributes from multiple alarms simultaneously. If the control system configuration supports the addition of user-defined fields, it may be capable of fulfilling the role of the master alarm database itself.

Following the recommendations for alarm deadbands and on/off delays from the standard (shown in Table 2) can help prevent nuisance alarms during operation.

A study by the ASM found that the use of on/off delays in combination with other configuration changes was able to reduce the alarm load on the operator by 45-90%.2 Configuration of alarm deadband (hysteresis), which is the change in signal from the alarm setpoint necessary to clear the alarm, can be optimised by a system that displays settings from multiple alarms at the same time, allowing them to be edited in bulk. This capability also makes it easy to review and update the settings after the system has been operating as recommended by the standard.

Similar tools and procedures can be used to configure the on/off delay, which is the time that a process measurement remains in the alarm/normal state before the alarm is annunciated/cleared.

The design of the HMI is critical for enabling the operator to detect, diagnose and respond to an alarm within the appropriate time frame. The proper use of colour, text and patterns directly affects the operator’s

performance. Since 8-12% of the male population is colourblind, it is important to follow the design recommendations shown in Table 3 to ensure that changes in alarm state (normal, acknowledged, unacknowledged, suppressed) are easily detected.

Symbols and faceplates provided with the system should comply with recommendations of ISA-18.2. Figure 2 shows an example where the unacknowledged alarm state can be clearly distinguished from the normal state by using both colour (yellow box) and symbol (the letter ‘W’). This ensures that even a colourblind operator can detect the alarm. The out-of-service state is also clearly indicated.

The standard recommends that the HMI should make it easy for the operator to navigate to the source of an alarm (single click) and provide powerful filtering capability within an alarm summary display.

Advanced alarming techniques can improve performance by ensuring that operators are presented with alarms only when they are relevant. Additional layers of logic, programming or modelling are configured to modify alarm attributes or suppression state dynamically. One method described in ISA-18.2 is state-based alarming, where alarm attributes are modified based on the operating state of the plant or a piece of equipment.

State-based alarming can be applied to many situations. It can suppress a low-flow alarm from the operator when it is caused by the trip of an associated pump. It can mask alarms coming from a unit or area that is shut down. In batch processes it can change which alarms are presented to the operator based on the phase (eg, running, hold, abort) or based on the recipe.

10 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

One of the most challenging times for an operator is dealing with the flood of alarms that occur during a major plant upset. When a distillation column crashes, tens to hundreds of alarms may be generated. To help the operator respond quickly and correctly, the system should be able to hide all but the most significant alarms during the upset. For example, logic in the controller can determine the state of the column. The state parameter could then be used to determine which alarms should be presented to the operator based on a preconfigured state matrix.

In Part 2 In part 2 of this article we will examine phases E though J of the alarm management life cycle (Implementation through to Audit).

References 1. ANSI/ISA-18.2-2009, Management of Alarm Systems for the Process Industries, www.isa.org 2. Zapata R and Andow P, Reducing the Severity of Alarm Floods, www.controlglobal.com 3. EEMUA 191 (2007), Alarm Systems: A Guide to Design, Management and Procurement Edition 2, The Engineering Equipment and Materials Users Association, www. eemua.co.uk 4. Abnormal Situation Management Consortium, www.asmconsortium.net 5. NAMUR (Interessengemeinschaft Automatisierungstechnik der Prozessindustrie), www.namur.de

Siemens Ltd Contact info and more items like this at wf.net.au/W022

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NEW PRODUCTS

POWER SOLID STATE RELAYS The Weidmuller electronic power solid state relays (PSSRs) deliver an unrestricted service life because they are wear free. The units have no mechanical contacts which can be worn away by arcs and sparks, ensuring their longevity. They are also highly shock and vibration resistant. Silent, they cause no disturbances and deliver good performance.

The single-phase models offer fast response times, and are far quicker than a mechanical switch. They also feature a large switching capacity - from 24 to 510 VAC - and also monitor high AC loads.

The optional, plug-on monitoring module warns users when current drops by 16% or more. It detects short circuits, line breaks and defective loads to help deliver peace of mind. The PSSR variant with a 35 A load current features a high l2 t load-current characteristic of 6000 A2s and can be used for inexpensive line protection with standard circuit breakers.

Further, the 70 A phase control unit with a 4-20 mA analog input allows users to set up heating controls or the power control of single-phase motors.

Robust and easy to use, the modules are available both with and without a heat sink and can be installed directly where needed at the site of application.

With a choice of eight devices customised to meet requirements, the units are suitable for use in the process industry, as well as in machine and plant manufacturing. The units can be used in trace heating, phase-fired controllers for motors, infrared heaters and permanent current monitoring.

Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/V876

Distributed diagnostics Field Diagnostics Module (FDM) from Phoenix Contact.

Analyze problems with your bus in the environment that is affecting it the most. Our Field Diagnostics Module for Foundation Fieldbus features: • Installation in the field using our innovative modular concept • Industry standard diagnostics • Single channel flexibility • Device management using DD, EDDL and DTM To learn more visit www.phoenixcontact.net/processfieldbus

© 2013 PhOenix COnTACT

1300 786 411 | phoenixcontact.com.au 13-0549DiagnosticsAd.indd 1

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 11

NEW PRODUCTS

PRESSURE CALIBRATORS Fluke has broadened its suite of precision pressure calibration products with the addition of 14 700G Series pressure gauges and two models of pressure calibrators: the 719Pro and 721 dual range pressure calibrators.

The 700G gauges can be combined with the company’s 700PTPK or 700HTPK pump kits for a complete pressure-testing solution for up to 600 psi (40 bar) with the PTP-1 pneumatic pump, and up to 10,000 psi (690 bar) with the HTP-2 hydraulic pump.

The 719Pro electric pressure calibrator is suitable for calibrating high-accuracy transmitters, pressure switches and pressure gauges. It features high-accuracy pressure measurements and an onboard electric pressure pump that can generate up to 300 psi (20 bar), eliminating the need for an external hand pump. It also measures, simulates and sources 4-20 mA loop current signals and can also measure up to 30 VDC. Its internal 24 loop power supply can power a transmitter under test.

The 721 dual range pressure calibrator with dual isolated pressure sensors allows technicians to take simultaneous static and differential pressure measurements in a single tool for gas custody and transfer applications. It can be configured by selecting either a 16 psi (1.1 bar) or 36 psi (2.48 bar) low pressure sensor and then adding any of seven high-pressure ranges including 100, 300, 500, 1000, 1500, 3000 or 5000 psi (6.9, 20, 24.5, 69, 103.4, 200, 345 bar).

Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/V829

12 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

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NEW PRODUCTS

VALVE FOR CORROSIVE AND ABRASIVE SLURRIES Flowrox has launched a pinch valve product designed to enhance current pipeline equipment and processes using the latest technology in fluid control. The PVG valve was developed for use in the oil and gas, mining, minerals and metallurgy, and wastewater industries - particularly where abrasive or corrosive slurries, powders or coarse substances are processed.

Flowrox has engineered its PVG valve at full bore with no flow restrictions, allowing processes with abrasive or corrosive fluids - such as lime slurry or mineral slurries. The main benefit of a full bore design is that the PVG valve itself becomes an integral part of the pipe and is able to process the same fluids in the harshest of conditions.

In addition to its strength and resistance to aggressive slurries, the PVG valve is designed as a full port fluid control device that allows a more efficient process, requiring less pumping energy. The reduction of head pressure is another benefit offered by the PVG valve, which helps reduce pump costs and eliminates unnecessary turbulence in pipelines handling abrasive slurries.

At the core of the PVG valve is its elastic sleeve, which is the only part in contact with the medium as a way to reduce any potential corrosion or deterioration due to wear and tear, even when processing the most corrosive chemicals.

Flowrox Pty Ltd

ACTUATORS WITH CANOPEN SUPPORT Exlar Corporation has released the CANopen communication protocol for its Tritex II product line. This enhancement allows the Tritex II to become an integral part of control architecture or machine control processes.

CANopen is available on Tritex II AC and Tritex II DC actuators.

The Tritex II with the CANopen network is intended to perform as a slave with a CANopen master. It does not have the features of a stand-alone indexer like other Tritex models. Set-up of the system is most easily achieved with the Expert software using the RS485 port. The latest revision of the Expert software supports all the Tritex products including CANopen and is available on the Exlar website for download.

Customer connections for CANopen are offered with either an M12 connector or wired directly to a terminal strip on the connection board with 75, 90 and 115 mm frame sizes.

Applied Automation Contact info and more items like this at wf.net.au/W025

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 13

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

DIGITAL COMPOUND GAUGE

>

The Noshok 1000 Series digital gauge allows local digital indication of pressure in place of mechanical gauges and provides 4000 h of battery life.

AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/W013

ULTRASONIC LEVEL SENSOR The Model ULSS ultrasonic level

>

sensor provides non-contact, continuous, temperature-compensated, short-range ultrasonic level measurement of fluids.

Dwyer Instruments (Aust) Pty Ltd

>

WF.NET.AU/W059

19″ RACK SWITCHES

These 19″ rack format switches fully comply with the IEC 61850-3 and

IEEE 1613

requirements for deployment in energy systems.

Phoenix Contact Pty Ltd

PORTABLE HYDROCARBON ANALYSER

>

WF.NET.AU/V830

The PetroSense PHA-100 portable hydrocarbon analyser allows for realtime measurement of petrochemical contamination in water or vapour.

TechRentals

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14 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

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WE KNOW WE CARE WE CUSTOMISE FOR YOU‌

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

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

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

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

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

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

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

Reliable products from reliable people!

NEW PRODUCTS

MULTIFUNCTIONAL STREAM SWITCHING SYSTEM A multifunctional stream switching system for process analytical instrumentation that is capable of integrating stream selection and filtering functions into one compact, modular assembly is available from the Instrumentation Products Division of Parker Hannifin.

The Gen II R-max system for gas and liquid analytical applications is based on the technology of its R-max stream switching system and incorporates numerous enhancements to further improve application flexibility, process integrity and serviceability. Backward compatibility allows the features of the Gen II R-max to be installed on existing R-max units very easily and quickly.

The system offers the flexibility of delivering multiple sample streams to an analytical system with a single, small footprint assembly. Other advantages include the system’s modular design, which simplifies configuration and maintenance, and the availability of normally closed, normally open and single 3-way configurations.

Enhancements include a captured vent that prevents cross contamination, an improved position indicator for quick recognition of valve actuation, easier removal of cartridges for maintenance, and an atmospheric reference vent module.

Designed to control both gases and liquids in analytical systems ranging from vacuum to 500 psig (34 bar), the system only requires 65 psig (5 bar) actuating air pressure.

The system uses surface mount technology to reduce leak paths, internal volume and dead volume. With surface mounting, system components can be easily removed and replaced without breaking process connections. In addition, the system features an internal self-purging outlet header that eliminates the need for an additional outlet loop.

Parker Hannifin (Aust) Pty Ltd Contact info and more items like this at wf.net.au/V924

CANOPEN SLAVE MODULE The ICP DAS I-8123W-CPS is a single-port CANopen slave module. As a stand-alone CAN controller, the module can represent an economic solution for CANopen applications

PRESSURE CONTROLLERS Rotork Instruments Fairchild range now offers the T9000 Series of I/P and E/P transducers that offer high accuracy with the capability to quickly customise the transducer for the exact application. The basic T9000 electro-pneumatic transducer attains accuracy of 0.5% or better and has a clear LCD screen with an integral keypad user interface. In addition, the T9000 offers simple PID tuning to easily calibrate and adjust for a multitude of operational parameters, such as the gain. The models can operate with an input signal of 0-10 VDC, 4-20 mA or DeviceNet and are equipped with standard tapped exhaust and fail freeze power failure mode features.

Configuring the base transducer in any one of its six available modular configurations, the series is designed to fit both the application and the budget, offering flow capacities from 1 to 800 SCFM, along with a wide variety of port sizes, port threads, input or output feedback, remote pressure sensing and other optional features. It handles supply pressures up to 200 psi supply with output ranges up to 150 psi.

Rotork Australia Contact info and more items like this at wf.net.au/V511

16 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

and be a CANopen slave device on a CANopen network.

The module has one independent CAN communication port with a 5-pin screw terminal connector, and has the ability to cover a wide range of CANopen applications. The module uses the Phillips SJA1000T and transceiver 82C250, which provide both CAN 2.0A and 2.0B specific, retransmission functionality, bus arbitration and error detection with auto correction.

It can be installed in the WinPACs, ViewPACs and XPACs Series. It is suitable for applications in the industrial automation, building automation, vehicle applications and embedded control networks.

ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/V930

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CASE STUDY

US Strategic Petroleum Reserve relies on magnetic flow meters for accurate brine disposal measurement With a capacity of 727 million barrels, the US Strategic Petroleum Reserve (SPR) is the world’s largest stockpile of government-owned emergency crude oil. Established after the 1973-74 oil embargo, the SPR provides the USA with a powerful response option should a disruption in oil supplies threaten the US economy. It is also the critical component for the United States to meet its International Energy Agency obligation to maintain emergency oil stocks and it provides a national defence fuel reserve.

The oil is stored in manmade salt domes created by injecting fresh water into salt deposits, which dissolves the salt, leaving an open cavern for storage. To retrieve oil from the salt caverns they pump water in the bottom, making the oil rise to the surface so it can be transferred to interstate pipelines or loaded into ships.

When oil is added into storage they pump the brine water out for disposal. DM Petroleum Operations Company, Inc manages and operates the SPR under contract to the US Department of Energy (DOE) and manages four storage sites: two in Louisiana and two in Texas.

The US Environmental Protection Agency (EPA) requires periodic integrity tests on each brine disposal line at the SPR’s site for leak detection. The flow rate is measured simultaneously at a point onshore and at a second point that is miles out into the Gulf of Mexico near the dispersion nozzles. The meters are transported by barge offshore, inserted for testing purposes, then removed from the line and stored until the next tests are conducted. The onshore and offshore flows measured by the flow meters are compared to determine if the pipeline has a leak. The criterion for a successful test is a difference of 4% or less between the two measurements.

Once each year, usually between May and June when the weather tends to be calm and before the hurricane season starts, the two lines in Texas are tested. The Big Hill Brine Line is a 22.5 km long, 48-inch diameter pipe and is one of the DOE’s toughest flow-metering applications. The second site is a 24-inch pipeline located approximately 9.5 km offshore. In the past, a pitot tube-type meter was used to profile the pipe and measure the flow at the two points. The valuable time required by divers to accomplish flow profiling on the gulf sea floor and less-than-satisfactory results

18 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

led to a search for a better means of measurement. The FPI Mag flow meters replaced the problematic pitot tube meters on 29 June, 1996. The recorded flows from the FPI Mag flow meters matched to within 0.21% and proved them as an excellent choice for the demanding task.

A lift boat - essentially a barge with legs - is used to transport the meters, crew and divers out to the offshore site.

Once at the site, the legs are lowered to lift the barge off the water, providing a stable working platform. Divers locate the opening in the pipe, which is at a depth of about 12 m for the Big Hill Brine Line, and insert the FPI meter sensor. Once inserted, brine is flowed through the pipe and the flow data is collected and recorded at oneminute intervals for a minimum two-hour test period.

The same type of test is conducted onshore simultaneously. The onshore crew connects McCrometer’s converter directly to a laptop to convert the electrical signal from the sensor to live flow rates. The integrated system then compares the offshore and onshore measurements. A difference of 4% or less is considered a successful test. The tests are submitted to the EPA, and it is with these results that the EPA determines whether to renew SPR’s discharge permit.

The original FPI Mag meters and subsequent generations of the product have been in continuous use for periodic testing service since their original adoption for this application. The latest test, again conducted with FPI Mag meters, confirms their performance results.

“For years we have counted on this flow meter to perform testing; to date we have always performed the tests successfully,” said James Nguyen, Senior Pipeline Engineer with DM. “Accuracy is extremely important to the testing process because of time and money”, said Nguyen. “We can’t afford to have equipment that is not working properly. The annual test cost for the contracting alone is $200,000 to cover the lift boat, a five-man diver team and equipment set-up. Plus we have our own offshore and onshore crews.”

AMS Instrumentation & Calibration Pty Ltd A longer and more detailed version of this article can be read online at wf.net.au/W079

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INSTRUMENTATION-SENSORS PRODUCTS

TEMPERATURE SENSOR The TS530 temperature sensor features an integrated resistance temperature detector (RTD), and combines the display, process connection and RTD all in a single part for fast and reliable performance.

Simple, push-button programming and large, highly visible LED displays ensure easy operation, while a rotatable display that can turn up to 340° allows for flexible viewing in the field. The sensor also sends feedback to a PLC, allowing operators to easily monitor measurement performance from virtually any location.

The temperature sensors feature a new design for easy mounting and installation, allowing users to mount them directly to a tank or pipe with no mounting bracket required using a ½ NPT process connection. For reliable performance in harsh manufacturing environments, the sensor meets IP69K protection ratings and operates in temperatures ranging from -50 to 150°C. Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/V827

2-WIRE LEVEL TRANSMITTERS Krohne Optiflex 2200 C and Optiwave 5200 C level meters are now available with 2-wire bus protocols Foundation fieldbus and Profibus PA. For each protocol, a dedicated PACTware DTM enables to access the device parameters directly via the instrument.

Bus protocols for Optiflex 2200 C TDR guided radar and Optiwave 5200 C FMCW radar level meters meet the latest Profibus PA Profile V3.02 and Foundation fieldbus ITK 6.1 interoperability testing.

The Profibus PA versions provide function blocks for level, distance, ullage conversion and volume conversion. The Foundation fieldbus protocol additionally supports link active scheduler (LAS) functionality that permits the use the level meters as master within an FF topology. Both versions meet FISCO safety model for ATEX/IECEx zone 0, 1 and 2 (Ex i as well as Ex d).

Optiflex 2200 C/F and Optiwave 5200 C/F are designed for the chemical, petrochemical, power, pulp and paper industries and comply with all applicable NAMUR standards (NE 21, 43, 107 and 53). Both level meters are approved for use in ATEX, IECEx, cFMus and NEPSI for intrinsically safe as well as in explosion-proof areas. Compact versions with analog output meet SIL2 requirements according to IEC 61508.

Krohne Australia Contact info and more items like this at wf.net.au/V832

20 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

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270x88mm HACH PACIFIC_ProcTech_HQd:layout

12/16/13

INSTRUMENTATION-SENSORS PRODUCTS

GAS FLOW COMPUTER

The ERZ 2000-NG flow computer and gas volume corrector from RMG by Honeywell is designed to provide a reliable and more intuitive solution for natural gas volume conversion in fiscal and secondary metering applications.

Featuring a graphical touch screen user interface, the flow computer enables gas distribution,

MADE FOR WATER. Hach’s operator-friendly HQd™ meters and IntelliCAL™ probes allow even new users to easily navigate without errors.

The durable design is built to do the job no matter where you put it to work.

HQd from Hach is the simplest way to get results you trust, with a durable design that is built to last.

transportation and storage service organisations to accurately measure gas flow, correct the measured volume, calculate energy consumption and provides all data via standardised protocols. It is certified by the European Measuring Instruments Directive (MID) as a gas volume and calorific value corrector for custody transfer metering of natural gases. The unit can easily be integrated in a gas train application in a cabinet along with gas chromatographs, flow computers, data loggers and controllers.

The device performs gas volume conversion on the basis of the equation-of-state for ideal gases.

Since this equation alone does not meet all the requirements for high-precision gas metering, the gas volume corrector also takes into account the characteristics of the real gas by using the K coef-

BOD • Conductivity • DO • ORP • pH Sodium • Ammonia • Ammonium Nitrate • Fluoride • Chloride

ficient as a correction factor. Such an approach is said to ensure utmost measurement accuracy and repeatability.

Designed as a universal instrument, it can be used for all metrological tasks in a gas metering station. It is available in a choice of system configurations, including: ERZ 2002-NG Density

1300 887 735 hachpacific.com.au

Volume Converter, ERZ 2004-NG State Volume Converter, ERZ 2104-NG State Calorific Value Volume Converter, ERZ 2102-NG Density Calorific Value Volume Converter and ERZ 2014/2114-NG Effective Pressure Gas Meter.

Honeywell Limited Contact info and more items like this at wf.net.au/V610

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 21

8:24 AM

INSTRUMENTATION-SENSORS PRODUCTS

12V VIBRATING FORK LEVEL SWITCH Emerson Process Management has announced a 12 VDC DPDT relay version of its Rosemount 2120 vibrating fork level switch for automated level monitoring and overspill protection of tanks or vessels in remote locations. The switch is said to be the first low-power switch to provide a built-in relay output - eliminating the need for a separate switching relay.

The 12 V switch is ideally suited to installations where there is no access to normal 24 V power supplies and the only power available is from batteries or solar-charged systems. The switch has all the features of the standard versions, including built-in instrument health/self-checking diagnostics, but is designed for use in 12 V low-power circuits.

Based on vibrating short fork technology, the switch is suitable for virtually all liquid applications and is unaffected by flow, turbulence, bubbles, foam, vibration or product variations. The `fast-drip’ fork design provides quicker and more reliable detection, especially in high-density liquids. Electronic self-checking and condition monitoring with heartbeat LED also give status and health information on the fork and sensor.

An adjustable switching delay virtually eliminates the risk for false switching in turbulent or splashing applications and the range includes various housings and wetted parts materials, with a complete range of process connections, extended fork lengths and overfill approvals.

With a temperature range up to 150°C and pressures up to 100 bar-g, the switch is suited to harsh process conditions including hazardous area installations.

Emerson Process Management Contact info and more items like this at wf.net.au/V834

INSTRUMENT FLOW TOTALISER SOFTWARE Sierra Instruments has released a flow totaliser software module for their QuadraTherm 640i/780i mass flow meters, available at no charge. Through their QuadraTherm Software Interface Program (SIP), end users now have an efficient management tool to totalise and monetise all gases with one instrument. The flow totaliser software module leverages QuadraTherm’s high accuracy (±0.5% of full scale) to give end users accurate totalisation of multiple gases from an industrial flow meter.

Key benefits of the software include: viewing the totalised value of multiple gases; being able to totalise up to four gases with one device and software package; being able to set units per pulse and pulse width; the ability to turn totalisers on and off; and to reset the totaliser.

There are four totalisers visible on the user interface screen of the SIP software. The user selects one to be active. Each totalizer is independent of the others, allowing users to totalise one gas, then switch and totalise another gas. End users can switch back to their previous gas to begin totalising flow with the previous flow total maintained or reset if necessary.

Procon Instrument Technology Contact info and more items like this at wf.net.au/V833

22 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

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INSTRUMENTATION-SENSORS PRODUCTS

MULTIPLE INSPECTION SENSOR UPDATE A free firmware update has been released for Banner Engineering’s iVu Plus TG. The easy-to-install software enables the simultaneous use of several match, area or blemish sensors across various regions of interest in a single inspection.

The iVu Plus TG Multipoint Software enhances the sensors’ reliability and accuracy. If the sensor identifies an incorrect or missing object when conducting an inspection, the software recognises it and alerts operators as to where the problem occurred. With the ability to monitor multiple inspections at once, users are able to streamline operations, while ensuring a precise inspection.

The device’s integrated touch screen vision sensors advance inspection capabilities with ethernet connectivity and multiple inspections. Ethernet connectivity enables sensors to share inspection data directly with PLCs, PCs or other factory devices, making communications and control even easier on the plant floor.

Capable of storing up to 30 inspections, the device can also accommodate rapid product changeover.

To tackle diverse inspections, the device can be configured to operate using four different sensor types. These types include Area, which verifies the presence of a feature or features of interest; Blemish, which identifies flaws on a part, such as scratches on a disc; Match, which verifies that a pattern, shape or part in any orientation matches a reference pattern; and Sort, which recognises and sorts as many as ten different patterns of parts, such as nuts, bolts and washers.

Micromax Pty Ltd Contact info and more items like this at wf.net.au/V506

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 23

INSTRUMENTATION-SENSORS PRODUCTS

RADAR LEVEL INSTRUMENTS Invensys has released the Foxboro Eckardt LevelWave Radar

CAPACITIVE SENSORS

Series measurement solution for liquids, including corrosive, sticky or difficult media.

Capacitive sensors detect bulk materials or liquids through

The series is measurement technology combined with

non-metallic vessel walls. Typical applications for the detection

robust, durable and reliable instrumentation. Each device

of these products can be found in the semiconductor, paper

has a unique 360° rotation, which allows for side or top

and wood industries. The KQ Series capacitive sensors allow

mounting as standard, making it much simpler to fit into

easy parameter setting via IO-Link and feature a clearly visible

an existing space. All LevelWave instruments also feature

display of the switching status.

a user-friendly external display, offering easy configuration

The parameters can be set either via the buttons on the sensor or via IO-Link interface. This can be done using a USB

for a new operator. There is also an option for full digital remote electronics up to a distance of 100 m.

interface or a memory plug. A standard M12 cable transmits

The measurement solution is suitable for a wide range of

process data, parameters and diagnostic information to a con-

applications, including blending; distillation tanks; process

nected IO-Link master.

tanks and separators; solid silos and storage tanks for most

When the ifm IO-Link unit

liquids; pastes; foam; and corrosive media.

is not in use, the sensor

Invensys Process Systems (Australia) Pty Ltd

works with one switching

Contact info and more items like this at wf.net.au/V879

output. ifm efector pty ltd Contact info and more items like this at wf.net.au/V615

SF6 SENSORS The GDT-20 and GDHT-20 transmitters from WIKA

Sensor Monitoring Services

Industrial Control ZigSense cloud controller is an

Energy Metering

Refrigeration

Tank & Silo Level

HVAC Cold Storage Building Automation Water Metering

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

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

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

Interface to other devices is Modbus ready.

Gas Monitoring

provide the foundation for continuous, digital monitoring of the quenching and insulating gas sulphur hexafluoride (SF6 ). They are designed to be used

Pollution

to give a clear indication

Horticulture

of the SF6 condition of gas-

Aquaculture

insulated equipment and thus enable maintenance to be planned solely on demand.

Based on precise pressure and temperature measurement, the two transmitters constantly calculate the density of SF6 so that leaks are identified at an early stage. The model GDHT20 also measures the gas humidity, so that the formation of corrosive decomposition products can be prevented. If the equipment is filled with SF6 gas mixtures, such as SF6 /N2 or SF6 /CF4, both instruments can be configured by the user.

The continuous monitoring of SF6 from the control room gives the foundation for condition-based, and thus costoptimised, equipment maintenance. The digitised measuring process brings a further advantage: by using the standard Modbus RTU protocol, the data of up to 247 instruments can be retrieved from a single master. In this way, the costs for wiring and implementation are significantly reduced in comparison with analog technology.

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

24 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

WIKA Australia Contact info and more items like this at wf.net.au/V828

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Direct Automation makes your job easier

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

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

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

The almost free micro PLC starting at only $99.00

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

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

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

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

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

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

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

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

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

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

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

•Download FREE CLICK PLC Programming Software Now! Analog I/O Modules •4-channel analog current & voltage input modules •4-channel RTD & thermocouple input modules •4-channel analog current and voltage output modules •4-channel analog current input / 2-channel analog current output module •4-channel analog voltage input / 2-channel analog voltage output module Australia Wide: 1-800-633040 New Zealand: 0-800-6330405 Asia Pacific: 61-7-55597600 E: sales@automationdirect.com.au Fax: 61-7-55252053 AutomationDirect is committed to bringing you the best automation products at prices that won’t break your budget.

www.automationdirect.com.au

CASE STUDY

Valve actuator retrofit for large-scale refinery upgrade Tupras is Turkey’s largest industrial company and leading refiner, operating four refineries of which the Izmit Refinery, in Kocael Province by the Sea of Marmara, is the largest. First opened in 1961, production at Izmit of commodities including LPG, naphtha, petrol, jet fuel, kerosene and diesel is now running at over 11 million tons a year.

As part of a massive expansion program - which also includes the construction of new refinery facilities on an adjacent site by the Spanish company Técnicas Reunidas - a major modernisation program is underway for the existing plant that includes a retrofit project that will deliver automated actuation and control for over 900 valves at the existing refinery’s tank farms. In addition, over 400 Rotork IQ electric actuators are being supplied through Rotork’s Spanish subsidiary company for the new adjacent site.

More than 900 ATEX Certified explosion-proof Rotork IQ intelligent electric valve actuators are being installed in a fourstage project to motorise manually operated valves on the existing refinery’s tank farms. Nearly 800 of the actuators will be retrofitted on existing valves while the balance will consist of new actuated valve packages. Many of the actuators will be factory fitted with intumescent fireproof coatings and all will be monitored and controlled on Pakscan two-wire digital networks.

Working from basic valve data collected from site, a full sizing service enables the actuator models to be matched to the valve requirements. This preliminary activity is followed by a detailed site survey to collect all the dimensions required to design the mechanical components required for mounting the actuators on the valves, together with associated cable runs and ancillaries.

The compact dimensions of the IQ actuator facilitate installation in limited spaces often encountered with crowded groups of valves as found, for example, on manifolds. Where access to a valve is severely restricted, safe remote-drive solutions are engineered, involving extension spindles, pedestals and adaptors, using wellproven methodologies and sound design principles.

With the addition of the Pakscan two-wire digital control system, Rotork is able to extend its retrofitting capabilities from the valve in the field into the control room. Designed specifically for the valve actuation environment, Pakscan provides a direct interface with host control and SCADA systems while simplifying the overall control network, optimising actuator functionality and increasing reliability.

The retrofit activity at Izmit is being performed by Rotork’s wellestablished agent in Turkey - Omas Teknik Pazarlama Temsilcilik.

Omas’s responsibilities include the design and fabrication of valve adaptation, installing the new actuators, commissioning and on-site support. The new actuated valve packages are being assembled and tested in the Omas workshops prior to delivery to site. The expertise, experience and comprehensive facilities available from Omas at a local level are key components in the success of this major retrofit project.

The risk of fire can be a serious cause of concern in a refinery, which can be minimised by the efficient and effective protection of vital systems such as actuators on critical isolation valves. For this reason, Rotork is providing a range of fireproofing options, allowing actuators to continue operating for significant periods of time in fire temperatures of over 1000°C.

26 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

The System-E intumescent coating system which has been adopted at Izmit has been specially developed and tested for use with IQ electric actuators. The factory-fitted coating is moulded to the actuator and in a fire will swell to between four and five times its original thickness to form a lava-like char that insulates the actuator and reflects heat back to the fire.

After the initial formation of the char, the coating remains passive until heat penetration through the char reaches a temperature at which the passive material is again activated. This process is repeated until the passive material is depleted or the fire is extinguished. This very effective thermal barrier is proven to repel 80-90% of the heat of a fire, providing protection for the actuator for more than 30 minutes at 1093°C. The weatherproof coating adds only minimal dimensions to the actuator, which retains all its design features and non-intrusive functionality.

The non-intrusive, explosion-proof and permanently watertight design of the Rotork IQ has a proven record of long-term reliability and low cost of ownership in the petrochemical industry. The use of solid-state electronics as an alternative to switch mechanisms and counter limiting devices, combined with programmable microprocessor based control and instrumentation functionality, offers many proven benefits.

Rotork is also providing a secure, non-intrusive, handheld instrument and a secure, bidirectional link to be utilised for setting control parameters, commissioning and downloading integral data loggers. This system is used to perform all the switch setting and commissioning functions that were traditionally only achieved by removing electrical covers. The same instrument can be used to download this data and upload it to other IQ actuators with similar commissioning parameters, simplifying and speeding up the operation, or to download actuator operating information from the actuator’s data logger to provide vital diagnostic information for asset management programs.

Rotork Australia A longer and more detailed version of this article can be read online at wf.net.au/W032

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NEW PRODUCTS

VISION GUIDANCE FOR ROBOTS ABB Integrated Vision is a smart camera system that makes vision-guided robotics applications faster and easier to deploy.

STAINLESS STEEL ENCLOSURES

Using 2D vision guidance, manufactur-

NHP has introduced a range of Eldon Multiflex 316

ers have the ability to track products

stainless steel enclosures which complete their range

more accurately, improve supply chain

of floor-standing cabinets.

management, improve quality, trouble-

Manufactured using leading-edge technology, the 316

shoot challenging lines and processes

stainless steel enclosure lines are designed to meet

and significantly expand their use of

highly demanding functional and aesthetic needs. With

robotic automation. Taken together, the

this in mind, the range is suited for use in the food

advantages of vision-guided robotics can

and pharmaceutical industries, outdoor applications and

significantly improve a company’s bottom line, saving time, money and resources.

marine environments as well as in other applications

The system, powered by Cognex, features sophisticated imaging technologies

requiring increased corrosion resistance.

such as Cognex’s PatMax algorithm for advanced part location. The result is

The 316 stainless steel floor-standing enclosure

robust inspection, defect detection, guidance, alignment and measurement which

range comprises bayable and welded enclosures with

are necessary to ensure manufactured products meet the highest standards.

standard dimensions ranging from 1800 x 600 x 500

RobotStudio, ABB’s PC-based programming tool, provides the platform for

mm up to 2000 x 1200 x 600 mm.

creating vision tasks quickly and easily. Operators can select features, set

The double door welded enclosures claim to offer

parameters and operate under real-world conditions from a library of common

an innovative design and the highest protection rating

vision applications. The smart camera offers a wide range of built-in commu-

NEMA4X/ IP66. The EKDS range comes with a welded

nication protocols that interface directly with the ABB robot, making it simple

vertical divider and individual doors with an independ-

to get a robot up and running.

ent locking system. The range is specially designed for

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/V878

use in sanitary wash-down production environments.

NHP Electrical Engineering Products Pty Ltd Contact info and more items like this at wf.net.au/W023

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 27

NEW PRODUCTS

CUSTOMISED EXPLOSION PROTECTION ENCLOSURE RANGE The Pepperl+Fuchs GOVAN explosion protection enclosure range is designed to provide the petrochemical, oil and gas industries with customised enclosure solutions, due to the flexibility to arrange enclosures in a modular configuration. With the enclosures having IECEx and ATEX certificates, most countries or plant owners’ specifications and certification requirements can be satisfied.

The enclosure certificates allow for the use of a wide range of electrical equipment, including cover-mounted controls, with a maximum number of possible cable entries for incoming and outgoing circuits.

The electrical equipment used in the GOVAN customised control panels, distribution boards and switch racks are well-known, quality brands designed to meet the requirements of the harsh operational environments in which they are used.

Flexibility of design means that Pepperl+Fuchs is able to work with users to supply solutions within constraints such as confined spaces in existing or in new plants. The solutions can be mounted on free-standing or wall-mounted frames, combining GOVAN enclosures having Ex d and Ex e explosion protection.

Qualified technicians wire the panels to the required specifications and schematics of the client and, on completion, functional and electrical testing is conducted by both Pepperl+Fuchs technicians and third-party inspectors where requested.

Pepperl+Fuchs (Aust) Pty Ltd Contact info and more items like this at wf.net.au/V595

HD35 SERIES WIRELESS DATA LOGGERS ■ 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.

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

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

28 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

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NEW PRODUCTS

EXTENDED PRESSURE RANGE VISCOMETER For oil, gas, and supercritical fluids, the VISCOlab

SIGNAL CONDITIONERS

PVT delivers accurate, fast and reliable viscosity

The Acromag TT230 and TT330 series of signal conditioners is designed to

measurements. In high-pressure environments, cor-

deliver flexibility while maintaining optimal performance. These isolated signal

rectly analysing precious samples is as challenging

conditioners feature high-density mounting on DIN rails, supporting RTD/

as it is critical. The high-pressure viscometer operates

resistance and potentiometer/thermistor input signals. With a convenient USB

at pressures up to 1378 bar (up to 2067 bar with a

connection to a PC, precise configuration using Windows software is simple.

special option), and controls temperatures from -5 to

Wiring terminals are front facing and removable for easy connections and

185°C with minimal warm-up time.

maintenance.

Safe and cost effective to own and operate, the

Each model accommodates a variety of signal types selected in the con-

device is mercury free and requires only 6 mL of

figuration software. The TT234 and TT334 models interface 100-100 kΩ via

sample. It also provides statistical certainty that

potentiometer/slide wire or 100-1 MΩ from a thermistor/rheostat. The TT235

ensures sample conditions are stable, accurate and

and TT335 models accept 100, 200, 500, or 1000 Ω platinum RTD; 120 Ω

repeatable. It measures gas and gas condensates in

nickel RTD; 10 Ω copper RTD; or 0-450 Ω linear resistance. All units effort-

addition to fluid samples.

lessly convert the input signals to a proportional current output signal of ±20,

The high-pressure viscometer combines a VISCOpro

0-20 or 4-20 mA. The TT330 series also allows for ±10 , ±5, 0-5 and 0-10

processor with either a Cambridge Viscosity 440 or 443

V output signals as well. The software allows users to precisely scale input

sensor. The 440 sensor provides continuous opera-

ranges for full resolution.

tion up to 1378 bar while the 443 sensor is designed

TT230 process signal converters have the option of loop power with a 2-wire

to operate up to 2067 bar. The system employs an

connection, or to be DC powered with a 3-wire con-

integrated recirculating bath for tight temperature

nection. TT330 process signal converters

control, and can run a sample in under four hours.

are DC powered (12-32 V) and support

High-quality viscosity data is critical for key res-

a bussed rail power option for

ervoir characteristics such as hydrocarbon volume,

primary or redundant power.

production/injection rates and recovery potential. This

The rugged design of these

information allows operations to know what it will

thin transmitters feature CE

take to get the crude out of the well and the quality

approval as well as: -40 to

of the oil find.

80°C operation, electrical

The VISCOlab PVT option is ideally suited for deep-

noise immunity and surge protection.

water wells, where pressures can be in the range of

Metromatics Pty Ltd

1000-2000 bar.

Contact info and more items like this at wf.net.au/V877

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/W019

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 29

NEW PRODUCTS

ALARM MANAGEMENT SUITE Honeywell’s DynAMo Alarm Suite is advanced alarm management software that reduces the overall number of alarms while helping operators focus and respond to the most critical.

According to the Abnormal Situation Management (ASM) Consortium, ineffective management of nuisance alarms (alarms that sound unnecessarily) can lead to incidents that cost the process industry billions of dollars, and pose an increased risk of fatigue and stress for operators who must constantly make instant decisions on how to respond when an alarm sounds.

According to the company, DynAMo Alarm Suite can be used to help users reduce overall alarm count by as much as 80%, identify maintenance issues, and increase visibility of critical alarms that require urgent attention. Its customisable, role-based dashboard enables operators, engineers and managers to view the health of their alarm system at a glance. A key feature of the software is that it is compatible with many mobile devices, enabling personnel to view alarm metrics at any time, from almost any location. This ease of access enables more frequent monitoring and faster corrective action, which helps alleviate a major fatigue factor of operators.

The software can be integrated with the company’s Experion Process Knowledge System (PKS), as well as any other control system. Honeywell also offers alarm management consulting, services and support, with worldwide coverage.

Honeywell Limited Contact info and more items like this at wf.net.au/V862

UHF RFID READ/WRITE HEAD The Q175 compact UHF RFID read/write head is designed to communicate with multiple data carriers, using both HF and UHF RFID technologies. This capability allows Turck to expand its RFID technology to accommodate diverse industrial production and logistic processes.

Featuring a ready-to-deploy design, the active read/write head supports the ISO 180006C and EPCglobal Gen 2 standards, and can be easily integrated into existing production lines. For optimal use in harsh applications, the Q175 combines its antenna and electronics in a robust IP67 aluminium housing.

It also allows direct mounting on metal, and can be utilised at high temperatures or in autoclaves.

The head can be operated on Turck’s modular and block BL ident RFID systems simultaneously with HF components.

Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/V507

30 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

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NEW PRODUCTS

PROCESS AUTOMATION SYSTEM Invensys has released its next-generation process automation system. With advanced tools and applications delivered across a high-speed, fault-tolerant and cyber-secure hardware platform, including the integration of the company’s Triconex safety system, the Foxboro Evo process automation system was designed to improve operational insight and integrity.

Foxboro Evo offers more powerful processing capacity and additional advanced applications to allow users to uncover new and hidden value from within their operations. It has evolved directly from the original Foxboro I/A Series and Triconex technology, and extends the layered architecture approach through a component object-based platform, which can undergo major upgrades without halting operations.

Because users can upgrade at their own pace, the Foxboro Evo system is claimed to deliver a low total cost of automation and high return on assets. Additionally, its applications improve the ability of plant personnel to contribute toward the success of the business by streamlining and contextualising the information they need to make the right business decisions at the right time.

The system includes a high-speed controller, field device management tools, a maintenance response centre, an enterprise historian, 1-n redundancy and cyber security hardening.

Current Foxboro I/A Series DCS users can migrate to the system with little or no downtime, depending on which version they are running.

Users of competing process automation systems, whose wiring terminations are still functional, can migrate to the system without ripping and replacing infrastructure, significantly reducing costs and downtime.

Invensys Process Systems (Australia) Pty Ltd Contact info and more items like this at wf.net.au/V932

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 31

NEW PRODUCTS

OEE REPORTING SOFTWARE ATS Intelligence software allows manufacturers to collect the data they need to calculate the OEE within their manufacturing process. It is designed to be a simple, robust and standardised OEE solution which combines extensive knowledge of manufacturers’ needs, proven best practices and technological trends.

Manufacturing intelligence and the calculation of metrics are playing an everincreasing part in the performance of manufacturing companies. The availability of production data is critical to the decisionmaking process. This is an area in which companies that do not have a standardised KPI framework in place need to invest.

The user interface of ATS Intelligence allows the operator to easily record all of the information required to calculate OEE in real time. Users only enter the information needed and, in return, get a quick and clear presentation of the OEE for each piece of equipment and for the whole plant.

The software enables users to collect and analyse the following data: the amount of material or product being manufactured; the machine or process manufacturing the product; the equipment’s optimum rate of production for each material; and the breakdown of reasons that reduce the total available time to the actual running time for a piece of equipment.

Using ATS Advanced Reporting Services, the details and nuances of all the information gathered can be explored using a web browser. This powerful tool allows users to view the OEE of everything, from an individual machine to an entire plant.

ATS Applied Tech Systems Contact info and more items like this at wf.net.au/V344

PROFINET-COMPATIBLE ETHERNET SWITCH Phoenix Contact has added a compact version to its range of automation switches to accommodate use in Profinet systems. The FL SMN 8TX-PN switch with eight 10/100 Mbps copper ports can be configured and diagnosed using the Profinet Device function in the PC Worx and Step 7 engineering tools. Due to automatic LLDP topology detection and the MRP redundancy mechanism, the switch is fully suitable for Conformance Class B Profinet networks.

The switches can be used in both Profinet and EtherNet/IP networks.

During initial start-up, the operating mode that contains the relevant functions of the particular protocol is activated by pressing a button.

The switches support the Media Redundancy Protocol (MRP) according to IEC 62439; for this, any device can act as a media redundancy manager (MRM) via an MRM plug. Furthermore, an interchangeable configuration memory module guarantees fast device replacement when a fault or malfunction occurs. In EtherNet/IP applications, the switches support the filter function based on IGMP snooping.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/V692

32 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

M40 POWER AND SIGNAL CONNECTORS Turck has introduced updated overmoulded M40 powerfast connectors, designed to deliver durable power connectivity in demanding environments. Offering a more robust connectivity solution than field-assembled versions, overmoulded M40 powerfast connectors are 100% factory tested to ensure optimal performance in harsh industrial automation applications.

The connectors feature both power and signal capabilities within the same connector, and are capable of up to 35 A. The M40 powerfast line offers male or female, straight connectors, standard and custom lengths and pigtails or extensions. For a complete system, the powerfast line also provides mating receptacles, cordsets, splitters and a jumper plug.

Allowing for a discrete or distributed power system, the powerfast connectors are suitable for power applications, including applications with motors, lights and heaters. The connectors feature a protection rating of IP67 for optimal protection against dust and water ingress.

Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/W033

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

ACI Connect is Australia’s new conference and exhibition focused on automation, control and instrumentation technology, advances and applications.

ACI Connect is brought to you by Westwick-Farrow Media, publisher of What's New In Process Technology and ProcessOnline.com.au, and developer of industry-specific events like the Industrial Technology Regional Roadshows and (Radio) Comms Connect www.Comms-Connect.com.au.

The ACI Connect Conference theme is Optimising Your Industry and will feature three dedicated streams over two days: • Industry Workshops — presented by technical experts, Frank Schrever (machine safety) and Steve McKay (instrumentation/electrical) • Technology@work — local case studies and technical solution papers from a variety of leading ACI specialists • Business and Engineering Connect — panels and papers on Cybersecurity, Ethernet in Industry, Skills Shortage, Industry 4.0 and more.

If you are an industrial technology professional looking to enhance your knowledge base, engage in hands-on workshops and see the latest products and technologies, then you need to be in Melbourne on April 9–10 at ACI Connect.

Exhibition space is strictly limited. For more information or to book your space, contact Narelle Granger — ngranger@westwick-farrow.com.au or (02) 9487 2700. * The full conference program will be posted on the website in mid February.

Organised by:

Association Partner:

www.ACIconnect.com.au

Media partner:

ECONOMICAL VACUUM SUPPLY IN MEAT PROCESSING PLANTS CENTRALISED PUMPING PROVIDES POTENTIAL SAVINGS WHEN GENERATING VACUUMS

An integrated packaging concept that guarantees that finished products are packaged hygienically, reliably, swiftly and efficiently is an important component in modern production of meat and sausage products.

I

nnovative meat processing plants are continuously working to optimise their production processes and integrate their packaging lines into the overall process in the best possible manner. The correct selection of vacuum generation systems substantially influences the operational reliability and cost effectiveness of the packaging process. There are various vacuum supply options depending on the size of the plant and the production quantities involved. These alternatives are detailed and considered below to find the best possible solution as regards technology and cost effectiveness.

Vacuum packaging of meat and sausage products offers a fundamental advantage: the elimination of the air in the packaging drastically reduces the oxygen content, slows down the activity of bacteria requiring oxygen, and thus significantly increases shelf life. Additionally, vacuum packaging is hygienic and enables the products to be presented in an attractive manner. A wide range of vacuum packaging machinery is available on the market, meaning that there is a suitable packaging machine for all packaging requirements. Regardless of their design or size, these packaging machines have one thing in common: for all machines, negative pressure must be generated to achieve the necessary vacuum in the packaging. This can be achieved by either an integrated or a separate vacuum pump. Other alternatives include central vacuum supply systems to which several packaging machines are connected.

34 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

Integrated vacuum pump Normally, the vacuum pump is integrated or set up separately in the immediate vicinity for all vacuum packaging machines - from the chamber machine to the thermoforming packaging machine.

Oil-lubricated rotary vane vacuum pumps are almost exclusively used for this purpose (Figure 1). This type of vacuum pump has long been a standard in vacuum packaging. Continuous further development ensures that these vacuum pumps are always state of the art, with millions in operation across the globe.

The vacuum pump, either integrated or set up separately to the packaging machine, is the simplest and most common way of generating the vacuum for packaging. Short pipes between the vacuum chamber, sealing station and the vacuum pump guarantee that the air is rapidly sucked out of the packaging. Larger-scale thermoforming packaging machines with high packaging volumes may also be fitted with a roots vacuum pump. The combination of vane and roots vacuum pumps means the pump-down time is shorter. In practice, this means shorter cycle times and thus a larger quantity of packaged products per time unit. If several thermoforming machines are operated, at least partial centralisation of the vacuum supply should be considered.

Partial centralisation With partial centralisation (Figure 2), the rotary vane vacuum pumps are removed from the actual packaging room and integrated into a

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Vacuum generation

turn, clearly improves the total energy consumption in favour of a centralised system.

Improved hygiene The removal of all vacuum generators in the production and/or packaging room in turn eliminates the danger of food contamination through oil aerosols. Additionally, there is no need for employees to enter the hygienically sensitive packaging room for maintenance or repair work. Clean-room conditions can therefore be created in the area surrounding the packaging lines.

Example: Primo Smallgoods

central pre-vacuum system for all packaging machines in a separate room. Dry-sealed roots vacuum pumps are installed directly in the packaging machines and connected to the central pre-vacuum generation system with a pipe system. This design ensures that the roots vacuum pumps operate at maximum efficiency and thus enable short pump-down times during packaging. Partial centralisation means the rotary vane vacuum pumps are eliminated from the production room, thus preventing the danger of aerosol emissions.

With a partially centralised system, it is always logical to physically locate and operate two to a maximum of five thermoforming packaging machines together. If more packaging machines are used, the investment costs are too high due to the roots vacuum pumps in the individual machines; thus it is recommended to fully centralise the vacuum supply.

Central vacuum supply Improved cost effectiveness Full centralisation of the vacuum supply (Figure 3) is generally an economically viable option from six packaging machines. Usually, it is safe to assume that substantially fewer vacuum pumps are required for a central vacuum supply than for a set-up of individual vacuum pumps directly beside the packaging lines. If the vacuum supply is subsequently converted from a decentralised to a centralised system, existing vacuum pumps can be integrated into the new centralised system, reducing the investment costs.

The substantially lower energy costs when using roots vacuum pumps should not be underestimated. The cooling requirements for the room climate is also reduced, due to the fact that all vacuum pumps are located outside the packaging room. This, in

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Busch Australia Pty Ltd supplied Primo Smallgoods, one of Australia’s largest producers of ham, bacon, salami and smallgoods, with a central vacuum system for Primo’s new factory located in Wacol, Queensland. The system capacity of the rough vacuum at 5000 m³/h at 50 mbar and the fine vacuum at 2000 m³/h at 5 mbar provides very fast evacuation time, therefore reducing the cycle time and increasing production rates. The Busch central vacuum system ensures economic efficiency by offering approximately 140 kW of power reduction. The system is also cost effective due to reduced maintenance costs - as there are fewer vacuum pumps installed; the reduction of installed vacuum pumps decreased from approximately 85 units to 23. In addition to this, by centralising the vacuum pumps, approximately 33 kW of heat load could be removed from the packaging room, saving money on refrigeration costs and reflecting on the energy savings of the central vacuum systems.

Operation method The individual packaging chambers are pumped out in two stages to be able to run maximum cycle frequencies on the packaging lines.

To do so, the critical pressure gradient is utilised and thus achieves the fastest possible evacuation. This requires a low vacuum pump station for the initial evacuation and a fine vacuum pump station for the evacuation on packaging pressure. The reversing valves with the corresponding control units are attached to the packaging machines to control the transition from a low to a fine vacuum.

The thermoforming vacuum pump station supplies the vacuum to the packaging machine moulding station. Here, the base film of the packaging is heated, sucked into the mould and shaped accordingly into packaging recesses.

On the one hand, this separation into various vacuum stations is necessary as the moulding and sealing functions run at different vacuums and, and on the other, as a substantially lower pump suction capacity is required for the two-stage evacuation of the sealing chamber.

FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 35

Vacuum generation

Figure 1: Cross-section of an oil-lubricated rotary vane vacuum pump R5 from Busch.

Figure 2: Partial centralisation of the vacuum supply: the roots vacuum pumps remain in the packaging machines, the vacuum pump stations to generate the low vacuum are set up in a separate machine room.

Figure 3: Full centralisation of the vacuum supply: all vacuum consumers are connected to the central vacuum system. There are no vacuum pumps in the production and packaging rooms.

Figure 4: Integration of the vacuum supply in the process control system enables permanent information about all relevant output data.

The pipework serves as a vacuum buffer. This buffer is necessary to keep the packaging pressure at a constant level, even when all the packaging machines are running with the same number of cycles.

The central vacuum system can be fully automatic - it activates individual vacuum modules if a greater vacuum is required or switches off individual vacuum modules if a smaller vacuum is required. If a vacuum pump fails in the low, fine or thermoforming pump stations, then the reserve pump can be automatically activated. This ensures maximum operational safety for the vacuum supply to the packaging machines.

meaning that the vacuum plant can be controlled and monitored from a PC. Any arising indicators highlighting imminent faults can be easily identified and rectified before the machines fail.

The necessary technical parameters can be permanently called up and the pressures in the vacuum lines are displayed in graph form. This allows all process-related data to be evaluated and archived. Valuable information is supplied to the quality assurance and repair departments.

Maintenance

In systems using two or more vacuum packaging machines, the operator or responsible head of operations should consider how the vacuum is generated. They should not forget that production (for example, with sausage fillers or tumblers) also requires vacuums that can likewise be supplied from a central vacuum supply, further improving efficiency.

The different vacuums and suction capacities at the various vacuum applications make it necessary for a vacuum specialist to precisely analyse the actual situation and then offer tailored solutions. It is important to engage specialist organisations that can offer expert advice and calculate precisely which vacuum solution is the most economically and technically viable for each individual case.

A central vacuum supply system has a modular design, meaning that individual modules can be disengaged for maintenance. When this happens, a reserve unit automatically activates. This means that maintenance work can be carried out during operation without affecting the production output of the packaging machines. In the centralised system, the individual rotary vane vacuum pumps are also subjected to substantially lower loads relative to the individual units, thus extending the maintenance intervals. The centralised system’s installation location outside the production area also benefits maintenance, as maintenance work does not result in interruptions to operational processes or in hygiene breaches.

Integration into the process control system Centralised vacuum supply systems are very well suited for integration into the operational process control system (Figure 4),

36 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

Summary

Busch Australia Pty Ltd Contact info and more items like this at wf.net.au/W040

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NEW PRODUCTS

HIGH-VOLUME SWAGING UNIT Engineered to streamline nut-ferrule installation, the Swagelok High-Volume Swaging Unit (HVSU) is aimed to increase safety and productivity for the oil and gas, alternative fuel and general industries.

The HVSU enables installers to easily preswage Swagelok nut-ferrule sets onto stainless steel tubing. The pneumatically driven and electronically controlled semiautomatic unit uses sensors to start and stop the process for consistent preswaging results.

This process provides several reliability and convenience features including automatic start when tubing is inserted and properly bottomed; prevention of over swaging with stroke-limiting tooling; easy switching from one tube fitting size to another with no tools needed to change sizes; and a high cycle life and cycle counter to facilitate preventive maintenance.

Swagelok Corporation Contact info and more items like this at wf.net.au/V841

HIGH-CURRENT FEED-THROUGH TERMINAL Phoenix Contact’s PWO 16pot high-current feedthrough terminal is a moulded terminal with a push-in connection. It consists of inner and outer parts which interlock through the housing panel without requiring any tools. The outer

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part provides wire connection via a push-in spring at a 45° angle; the inner part provides connection via a straight ring cable lug.

The high-current feedthrough terminal can handle currents up to 76 A and voltages up to 1000 V. Despite its compact

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dimensions, the moulded terminal - or terminal with suitable spacer plates - fully complies with the 600 V UL requirements according to UL 1059.

The push-in spring provides fast and tool-free connection of wires with diameters ranging from 1.5 to 16 mm2. Rigid wires and wires with ferrules are simply inserted into the clamping point, where the spring securely pushes them against the current bar. To without ferrules, the terminal is held open using a standard screwdriver.

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connect finely stranded wires

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 37

NEW PRODUCTS

ENHANCED MACHINE DESIGN TOOLS Rockwell Automation has enhanced its free Connected Components Accelerator Toolkit (CCAT) and Connected Components Workbench software tools. Machine builders are under constant pressure to design products in a more cost-effective manner and deliver them faster. Competitive pressures are even higher for builders of simple control, standalone machines. The enhanced, time-saving tools integrate the entire machine-control development process, which creates capacity for builders to focus on developing the proprietary features and functions that differentiate their

EMBEDDED COMPUTER

machines from competitors.

IEI Technology’s ECW-281B-D2550 fanless embedded com-

The CCAT is a one-stop solution for stand-alone machine

puter is designed for rugged applications with limited space.

control design and implementation. A clear start page directs

It features Intel’s Atom D2550 Dual-Core 1.86 GHz CPU, Intel

users through the dropdown menu of options. Machine

NM10 Express chip set and includes 2 GB DDR3 SO-DIMM

builders simply choose their controller and the toolkit pro-

system memory.

vides a full suite of compatible components and application

The device supports four COM ports (three RS232 and one

development tools, including a list of compatible materials;

RS422/485), four USB 2.0 ports, two gigabit ethernet ports,

panel layout and wiring drawings (usable in CAD software);

a VGA port and an audio jack to simplify connectivity to a

prewritten control programs; quick-start guides; and sample

variety of external peripheral devices. The 2.5″ SATA bay can

HMI screens, including diagnostics.

support a solid state disk or hard disk drive.

In addition, the free tool kit now provides a bill of mate-

Expansion is available via two PCIe mini slots (one full-size

rials electronically, allowing easy transfers to the Rockwell

and one half-size), plus an optional 2T2R 802.11b/g/n wireless

Automation Proposal Works software. This software helps

module is available for greater connectivity.

machine builders find exact catalogue numbers for Allen-

The device meets the MIL-STD-810F shock and vibration

Bradley products and services, access current pricing and

specifications for rugged environments. In addition, the small

build a proposal document.

footprint of only 229 x 132 mm allows it to be easily integrated

Once machine panels are designed and built from the

into applications with limited space.

CCAT-provided bill of materials, the Connected Components

The flexible mounting options allow the embedded system

Workbench software enables machine builders to program

to be DIN rail, VESA 100 or wall mounted to suit a variety of

controllers, configure devices and design HMI screens.

applications such as automation, digital signage and process

Rockwell Automation has expanded the software’s pro-

control.

gramming capabilities to include the recent Allen-Bradley

The product includes the company’s One Key Recovery

Micro850 controllers, PowerFlex 523 AC drive and PanelView

software solution, which eliminates the frustration of system

Component graphic terminals.

recovery after unexpected system failure.

Rockwell Automation Australia

ICP Electronics Australia Pty Ltd

Contact info and more items like this at wf.net.au/V679

Contact info and more items like this at wf.net.au/W027

38 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

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NEW PRODUCTS

RUGGED TABLET PC The Ubiqconn uTablet T70C is a 7″ IP65 rugged tablet PC designed for field applications. It meets the MIL-STD-810G rating for shock and vibration and can be dropped from 1.6 m onto plywood or concrete surfaces. It is fully sealed against the ingress of liquid and dust and has an operating temperature rating of -20 to +50°C. The 7″ LED backlit screen with integrated 5-wire resistive touch screen features a display brightness of 400 nits with optional 500 nits sunlight-readable functionality for outdoor applications.

The tablet PC is based on Intel&#rsquo;s Atom N2600 1.6 GHz Dual Core CPU and includes 2 GB of DDR3 SODIM and 32 GB of upgradeable SATA solid state disk. The hot-swappable dual batteries offer up to eight hours of battery life.

A 5 megapixel webcam with an LED light is embedded in the rear bezel and a 2 megapixel camera with audio input is in the front panel. Seamless communication is available via the onboard GPS or optional 3.5G or 4G TLE modules.

The tablet is available with an optional 1D/2D barcode scanner and magnetic stripe reader (MSR) suitable for portable stock and asset management.

Multiple connectivity interfaces include two USB ports, an RS232 port, an audio jack, one MicroSD slot and an ethernet port supporting the PXE function. Five programmable function buttons are located on the front panel.

Vehicle and desktop docking stations are available as an optional accessory.

Backplane Systems Technology Pty Ltd Contact info and more items like this at wf.net.au/V925

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 39

CASE STUDY

Coal conveyor with lower environmental impact The Ellton Group has completed the construction of a 2 km coal conveyor system for Rio Tinto Coal Australia’s Coal and Allied Hunter Valley Operations.

The 1400 mm belt conveyor system rated at 2400 TH includes an overland conveyor and a skyline stacker conveyor system that eliminates the previous need for heavy trucks to transfer coal from another load-out facility during peak production.

The conveyor design also overcomes numerous environmental and structural challenges as it traverses reclaimed and subsidenceprone land to deliver high volumes of coal to an existing stockpile facility through a cost-efficient design that incorporates recycled previous structures.

“One of the many unique aspects of the design was the complete incorporation of an existing skyline gantry system contained within the new structure,” said the Mark Elliott, Managing Director of the Ellton Group.

“The old gantry had a tripper running through it. We built our new, higher-capacity structure around the existing tripper gantry, running the conveyor in the opposite direction but sharing a radically improved and strengthened structure that easily and safely handles higher conveyor loadings but is designed to minimise additional mass and wind loadings.”

Working in consultation with Rio Tinto’s operations staff and their consultants, the Ellton Group developed various options that made good use of existing infrastructure while observing Rio’s safety and environmental standards.

“That’s the sort of thing you can do as a younger, nimble and innovative supplier. While we have had plenty of experience, particularly in the Hunter Valley, we are not bound to old ways of doing things or regimented thinking that says we have to tear down everything that’s already there and start again. As a company committed to efficiency, sustainability and minimising the impact on the environment, I think Rio Tinto were impressed by our close attention to their wishes”, explained Elliott.

The overland conveyor needed to pass above extensive areas of reclaimed and previously mined land that is prone to subsidence.

Safe and efficient design of the trestle structures carrying the conveyor included trestle structures and roof sections that were not only structurally independent of each other, but also independently adjustable in three dimensions.

Maximum use of existing infrastructure was a prime objective.

However, wanting to incorporate existing structures in the final design that were not originally rated for the revised duty, was only part of the design challenge. The upgrade works had to occur while the existing plant continued to operate so the new design had to

40 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

be suitable for construction in and around equipment that could not be stopped or demolished.

Minimised additional wind and mass loading on the existing structure was achieved by adopting a ‘wrap-around’ gantry design to support the new conveyor and tripper. The gantry design had to be as light as possible and still allow the existing tripper to operate inside the old gantry both during and following construction.

Rio Tinto also had extensive requirements for containment and protection of the load and the surrounding environment. In addition to full coverage of the conveyed load to minimise spillage and dust, the areas traversed by the overland conveyor are protected by civil works including bunding, side dish drains, channelling and settlement ponds. These works separate and redirect clean water run-off from the surrounding landscape to avoid possible contamination, and capture water emanating from the conveyor path and direct it to one of several dirty-water settlement ponds constructed along the route. By containing run-off and run-on, recycling is optimised and contamination of the environment is avoided.

Ellton Group also re-used old gantry structures, which were stripped, refurbished, painted and refitted to new standards and incorporated into the elevated stages of the overland conveyor.

The fully enclosed tipper feed structure now also spans a busy local road, removing the need for trucking by providing a clean and safe alternative.

Bonfiglioli Power Pack heavy-duty, fully coupled drive combinations were used.

“The drives were specified by Bonfiglioli Business Development Manager Kris Jaryn with whom we have worked well before,” said Elliott. “Bonfiglioli is a respected supplier that gave us what we needed when we needed it, to provide on-time performance.” The drives and take-ups were mounted at ground level, rather than with elevated drives and vertical take-ups, for ease and safety of maintenance. “A problem with off-ground mounting is that access is difficult and it is hard to isolate the belt and remove the energy load from within it,” explained Elliott.

“With our on-ground concept, it is simple and safe to detension the belt and remove the stored energy, thus enhancing safety. The hazards associated with isolating suspended gravity weights are removed. The design - which reflects our experience in underground mining - also provides better and quicker access for maintenance,” said Elliott.

Bonfiglioli Transmission Pty Ltd Contact info and more items like this at wf.net.au/V744

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NEW PRODUCTS

TEMPERATURE ISOLATION MODULES Weidmuller has expanded its ACT20M 6 mm temperature isolation and conversion module range. The six new models are available as thermocouple or RTD stand-alone units as well as combined RTD and thermocouple models. Users can also choose between isolated and non-isolated models.

All the temperature models are available as output loop-powered or 24 VDC powered units. They also feature a DIP switch selection for zero, the full-scale range setting and output selection.

The RTD and thermocouple devices are said to be very reliable and offer a high accuracy reading to within 0.1% of measuring range. Depending on the unit, the measuring range is from -200 to +1370째C. The operating temperature range is -25 to +70째C to ensure the units meet demanding applications. The output voltage is selectable from 0-5, 1-5, 0-10 and 1-10 V and the current can be adjusted between 0-20 or 4-20 mA. The output response times are set at 30 ms intervals.

For maximum convenience, the models measure only 6 mm in width, and are quite small and compact. They are suitable for use in industrial, automation and mining applications.

They also provide 2.5 kV as well as three-way isolation (between input/output/power supply). 24 VDC can be supplied via a DIN rail bus that eliminates individual wiring and minimises installation time.

Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/V929

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FEBRUARY 2014 WHAT'S NEW IN PROCESS TECHNOLOGY 41

AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265

SUSTAINABILITY – THE KEY TO SUCCESS

L

ast year was a challenging year for Australia’s mining industry as companies faced volatile commodity prices, increasing global supply coming online and shareholders with limited appetite for risk.

Australia’s miners are under increased pressure to ensure more sustainable operations through increased productivity and better cost management. The sprint for production expansion at any cost is very much changing into a sustainable production at manageable cost marathon.

While most of the market fundamentals driving increased global demand are still prevalent, it is clear that only the companies which are able to manage cost along their entire supply chain, and manage production and scheduling based on better demand forecasting, will have the sustainable business model to thrive.

Australian miners face some of the highest costs on the planet. As such, the focus on automation as a key to improving productivity levels, and information availability to aid better real-time decision making, are non-negotiable. Vendors able to provide their customers with solutions that aid decision making in all aspects - from energy utilisation, production and asset management, through to supply chain optimisation - hold the key to facing some of the industry’s biggest challenges.

Reducing costs needs to be undertaken as a journey, not a knee-jerk reaction to market fluctuations. One of the key enablers of this is an understanding of costs with context - for example, energy costs in the context of production, and in the context of supply constraints and demand requirements.

Every component in the plant that provides information makes up a piece of this puzzle and can ultimately aid in an intelligent decision-making process about where to optimise, gain efficiencies or reduce costs.

Increasingly, there is a need to provide these solutions within the context of real-time supply and demand forces and constraints. Vendors that provide these integrated solutions are conscious of the need

www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

for open integration. Customers using a single vendor solution have an expectation there will be added value such as out-of-the-box integration, better diagnostics, more context to data, better support, etc. However, this still needs to be based on open technologies and industry standards to allow easy integration of third-party systems and allow customers best-of-breed choice.

Investment into new and current mining operations has to be made with these fundamentals in mind to ensure the long-term sustainability of the operation. For new projects, this approach will ultimately ensure the creation of integrated intelligent operations, enabling optimum productivity and controlled quality. For existing operations, the ability to sweat your assets by extending their life through better asset management and increasing the value of their input to decision-making toolsets will ensure the best possible return on investment.

Mining companies cannot change market conditions or global trends; however, they can change the way they operate and base their decision-making on sound contextual data, leading to sustainable operations in any market environment.

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

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

Rocco de Villiers has been involved in the automation and optimisation industry for 25 years.

Currently General Manager Marketing and Operations, Industry Business at Schneider Electric and based in Sydney, he has been with the company for approximately five years. Prior to this role, he was based in Adelaide and then Brisbane as the industry sales manager for SA/NT and then Queensland.

42 WHAT'S NEW IN PROCESS TECHNOLOGY FEBRUARY 2014

September 2013 total CAB audited circulation (Aust + NZ) 6,781 readers (80% personally requested)

Contact the editor

Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP100007403 ISSN No. 0819-5447 All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them.

Information indicating that products are made in Australia or New Zealand is supplied by the source company.

Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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List (A) Job Function 1 Management - Corporate/General 2 Management - Manufacturing/ Engineering/Specialist 3 Engineer - Electrical 4 Engineer - Electronics 5 Engineer - Process 6 Engineer - Project 7 Purchasing/Procurement 8 Technician - Maintenance/Service 9 Technician - IT 10 Technical Officer 11 Scientific Officer - R&D 12 Scientific Officer - QA 13 Consultant 14 Contractor/Tradesperson 15 OHS/EHS 16 Education/Training 17 Student-Undergraduate/Apprentice 18 Analyst 19 Sales/Marketing

List (B) Industry 1 Agriculture/Rural 2 Building/Construction 3 Chemicals/Allied Products 4 Communications Systems 5 Defence/Military 6 Education 7 Emergency Services/Law Enforcement/Security 8 Engineering Services 9 Environmental Services 10 Finance/Banking/Insurance/Legal 11 Food Industry - Bakery 12 Food Industry - Beverages 13 Food Industry - Confectionery 14 Food Industry - Dairy 15 Food Industry - Fruit & Vegetables 16 Food Industry - Meat 17 Government - Federal 18 Government - State 19 Government - Local 20 Health/Hospital 21 Instrumentalities (eg CSIRO) 22 IT - Networking 23 IT - Security 24 IT - Storage 25 IT - Wireless 26 Laboratory - Analytical 27 Laboratory - Clinical/Medical 28 Laboratory - Life Sciences 29 Logistics/Transport/Warehouse 30 Manufacturing 31 Mining 32 Oil/Gas/Coal 33 Packaging 34 Processing 35 Retail/Wholesale/Hire 36 Service/Maintenance 37 Telecommunication 38 Testing/Certification (eg NATA) 39 Utilities

Becker Natural Gas Solutions METERING AND REGULATION STATION OBJECTIVES:     

Cost effective design Reduction of fugitive bleed-gas emissions Stable pressure and/or flow delivery Limit noise to regulatory levels Minimise maintenance cycles

BECKER T-BALL FEATURES AND BENEFITS:  Size range 2¨ to 42¨ – ANSI Class 150 to 2500#  High capacity CV range: 2 to 249,000  High rangeability, up to 300:1, maintains accurate control with less runs  Noise attenuating design reduces noise by 35 DB(A)  Self-cleaning, clog-resistant design reduces maintenance  Low emission stem design, eliminates fugitive emissions!  Small dimensional envelope minimises Station footprint.

AND THERE’S MORE…

Only Becker’s VRP Pilots, Positioners and Controllers provide a zero-bleed or bleed-to-pressure solution.

Don’t waste Natural Gas! Contact us for information on our valve emissions calculator…

Reduce your carbon emissions and save money with our VRP retrofit program.

email: sales@powerflo.com.au tel: 1300 658 701

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