What’s New in Process Technology Mar 2013 by Westwick-Farrow Media

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ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY MARCH 2013

CONTENTS

GEâ&#x20AC;&#x2122;s Mooney Flowgrid Regulator is an easy-tomaintain, self-contained, pilot-operated regulator that allows users to maintain pressure and flow control of almost any gas or liquid. The ability to control pressure and flow increases accuracy of use, responsiveness and stabil-

The advance of the robots Helping manufacturers become more competitive

maintenance and energy costs. Combined with

New products

top-entry access to all components, the Mooney

Hot products online

looking to produce energy more efficiently and

Choices in automated level detection

As I see it

design helps prevent debris from accumulating

The truth about compressed air audits

under the seat and affecting the tight shut-

Part 2

ity while decreasing parts, noise levels and

Flowgrid Regulator adds value for customers reliably, with less expense and greater awareness of environmental responsibility. The unique Flowgrid symmetrical throttle plate

off capabilities of the regulator. Drilled or stepped hole throttle plates reduce noise and help extend diaphragm life, even in high turndown applications, with a wide range of trim capacity options. The rugged fabric-reinforced throttling element/diaphragm provides flexibility, stability and fast response time in severe service conditions and the elliptical main spring provides a high frequency response, a proportional action for stability, as well as a consistent low minimum differential and shutoff force. The equal inlet/outlet pressure rating for all sizes assures easy operation without requiring special startup procedures, and the compact size of these valves makes for ease of installation in any position. Optionally, they can be fitted with a slam-shut device, for secondary downstream pressure protection, having both over- and underpressure protection options. Powerflo Solutions Pty Ltd www.powerflow.com.au

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THE ADVANCE OF THE ROBOTS HELPING MANUFACTURERS BECOME MORE COMPETITIVE Glenn Johnson, Editor

4 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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©stock.xchng.com/ CJILLIC

Industrial robot technology has come a long way from the simple machines of the early ’60s and today offers more flexibility and cost-effectiveness than ever before. Can Australian manufacturing capitalise on the benefits?

he first industrial robot to be used in manufacturing was installed at a General Motors plant in New Jersey in 1961. The Unimate robot had a single non-articulated arm and weighed more than 1.8 t. It was used for a single task - to move hot die-cast metal parts - and ran from a program on a metal drum. It had a 227 kg maximum payload. Industrial robots have evolved greatly from that time. The types of industrial robots commonly in use today can have as many as six degrees of freedom of movement and can be programmed for complex tasks by lead-though teaching. The largest robots can handle payloads of over 1300 kg and the smallest can be as light as 14 kg. New robots are just becoming available that can work collaboratively and safely in conjunction with a human worker.

Market trends With evolutionary progress in robot capabilities and lowering cost, the industrial robot market has seen a continuous upward trend. Like many other forms of investment, the rate of uptake of industrial robotics tends to follow economic trends: for example, the rate of investment in robotics was markedly down in 2009 due to the GFC, but in 2011 reached its greatest ever peak of around 166,028 units - an increase of over 38% from the previous year (see Figure 2). The International Federation of Robotics (IFR) in August 2012 predicted a 9% growth to 181,000 units for 2012 and believes the average will be 5% growth per annum, with the annual supply of industrial robots reaching 200,000 in 2015.1 The automotive and electronics industries still remain the leaders in the use of industrial robotics worldwide and so the uptake of robotics is particularly marked in countries that have strong automotive and electronics industries. Worldwide, the manufacturing industry average industrial robot density is about 55 robots per 10,000 employees; but in Japan, South Korea and Germany, the density is much greater: between 347 and 261 per 10,000 employees. As it is in so many other areas, China is rising quickly in the uptake of industrial robots and is now the fastest growing market. In 2011, almost 22,600 robots were supplied to China, and it is expected to be the top robot market in the world by 2014. There is also a fledgling local robotics industry

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developing there. Other ASEAN countries are also increasing their investment in robotics, as well as the countries of Eastern Europe, India and Brazil.

Industrial robotics in Australia In comparison with the rest of the world, Australia is sitting at the world average level of just over 55 per 10,000 employees and New Zealand is much lower at about 24. This is an interesting statistic for Australia, but not very surprising considering the heavy economic dependency on industries other than manufacturing, and the current decline in the automotive industry. The Prime Minister’s Manufacturing Taskforce Report of the Non-Government Members (August 2012) stated that Australian manufacturing is largely made up of small firms: “More than 500,000 Australians work for small and medium-sized manufacturing businesses. Around 50,000 manufacturing SMEs employ less than 200 people … This is a systemic constraint that makes it harder to penetrate global value chains within which much of manufacturing’s value is created. An industry structure featuring disproportionately small firms means fewer economies of scale and lower productivity.”3 With a preponderance of small manufacturers and therefore fewer economies of scale, it would seem natural that the ability for these manufacturers to invest in robotics and other automation may be more limited than in countries with larger domestic markets and correspondingly larger manufacturers. But as stated above, the cost of robotics is continuing to decrease and newer types of lightweight assistive robots and robotic ‘smart tools’ are becoming more available, so it may well be that Australian manufacturers with a view to future survival will need to be more technologically innovative and move to adopt these newer technologies.

Making first-world manufacturing more competitive The opening up of new consumer markets in Asia, South America and the Middle East is creating an increasing consumer demand for higher quality manufactured products at lower cost, so for developed nations with high standards of living and high labour costs, the need to find competitive advantage is paramount in order to sustain a manufacturing industry. According to the IFS:

MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Robotics

Figure 2: Estimated worldwide annual shipments of industrial robots. Source: IFR Statistical Department.

Figure 1: The first Unimate robot being prepared for shipment to GM.

Figure 3: Number of multipurpose industrial robots (all types) per 10,000 employees in the manufacturing industry. Source: IFR statistical Department. “Increased productivity will be required to offset labour shortage and higher costs associated with demographic shift in many countries. Sustainability, eco-friendly production and energy-saving measures are gaining an increasing importance all over the world. New production processes have to be installed. Automation provides solutions to all these challenges and industrial robots are key components of automation.”4 The advantages of robotics and other automation are numerous, but traditionally they have been used to replace humans in dirty, dangerous and tedious work (such as in packaging and logistics, and in welding) or to produce quality work with accuracy and speed in large volume tedious assembly operations. Normally, these types of applications are the domain of larger robots with fixed installations, performing a single task, and so the volume of work needs to be large enough to justify their expense. But improving technology and the decreasing cost of robots now provides an opportunity for helping to protect local manufacturing employment. The potential afforded by robots and automation is that the total cost of local production can be kept equal to or lower than the cost of overseas manufacturing (when transport costs are taken into account) and provides other benefits such as local service and support for the products, actually increasing

employment. Many people may be concerned with the potential loss of jobs brought about by replacing people with machines, but after all, a manufacturer that cannot compete with imported goods will go out of business and not employ anyone at all. Staying competitive through a more innovative use of technology can keep a company’s doors open and perhaps even increase the number of available positions to support increased business needs. This appears to have been recognised in the USA. Currently, the use of industrial robots in the USA is only about half that of Japan and Germany per capita, and over the 10 years from 2001, more than 2.1 million jobs were lost in the US manufacturing industry due to trade with China. The USA is now undergoing a phase of increasing its automation and robotics usage, reaching a new peak in investment in 2011. The US manufacturing industry appears to have recognised that if it wants to stay competitive and maintain employment during the ‘Asian century’, then it needs to increase investment in automation. It would seem that it is time for Australian manufacturing to take a similar approach.

Help from the next generation of robots According to Alberto Elfes, Science Leader for Robotics at CSIRO, the newer generation

6 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

of lightweight, assistive robots may provide new options for small to medium enterprises (SMEs) to improve their competitiveness: “Assistive robotics offer a high-productivity solution that could also help Australian manufacturing integrate into regional value chains, as recommended in the recent Asian century white paper.”5 Elfes says that there are three ways that lightweight robots can be integrated as assistants to workers: • As ‘intelligent tools’ that work together with human workers - mobile assistants; manipulators; smart picking, lifting and handling systems; robotic welders, gluers and assemblers. • As tools to augment the abilities of humans - powered exoskeletons to increase strength; wearable machine vision systems to improve safety; mobile assistive trainers. • As smart field tools - enabling workers to work under hazardous and challenging conditions remotely; micromanipulation for working with very small objects; reduction of work-related injury such as repetitive strain. These newer types of robots are the result in advances in materials technology, microelectronics, vision technology and mechatronics. In contrast to the well-established fixed, heavy, single-task robots we are familiar with: • they are smaller, lighter and ‘smarter’ than their traditional counterparts;

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Robotics

Figure 4: Australian Exports by Sector 2011. Source: Department of Foreign Affairs and Trade.

Figure 5: FRIDA assistance robot concept. Source: ABB.

• they can ‘see’ their environment with cameras, precision sensors and perception algorithms; • they are capable of mobility, and can navigate within workplaces; • they can be communicated with via voice and gestures and remotely manipulated by humans. Last year on ProcessOnline, we reported research sponsored by Boeing being conducted at MIT into how robotic assistants could be used to perform tasks that would hinder a human’s efficiency, with a focus on aircraft manufacturing.6 “It’s really hard to make robots do careful refinishing tasks that people do really well. But providing robotic assistants to do the non-value-added work can actually increase the productivity of the overall factory,” said Professor Julie Shah, leader of Interactive Robotics Group at MIT’s Computer Science and Artificial Intelligence Laboratory. “If the robot can provide tools and materials so the person doesn’t have to walk over to pick up parts and walk back to the plane, you can significantly reduce the idle time of the person,” she says. Another example of an assistive robot is ABB’s dual-arm concept robot, FRIDA, which was introduced as a concept in late 2012.7 It consists of a torso with integrated controller, two arms (with seven axes each) and grippers capable of handling a wide range

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of parts. The arms have a reach similar to that of a small adult and the weight of the robot is small enough to make it portable. Such a robot can be mounted on a workbench or hung from a wall and is capable of operating in tight spaces and reaching components below its base and behind its back.

A light amid the doom and gloom? Alberto Elfes feels there is some room for optimism among the doom and gloom that currently makes up the debate about Australian

manufacturing. Perhaps he is right: if Australian businesses can find the funds to support greater use of modern and soon-to-be-here technology in automation and robotics, then perhaps there is a chance they can improve their competitiveness to meet the challenges of the Asian century, and help to maintain employment in the manufacturing industry. Change is inevitable - the difference between success and failure may well lie in the ability to embrace and manage change rather than fearing it and letting it happen on its own terms.

References: 1. International Federation of Robotics 2012, The continuing success story of industrial robots, <http://www.worldrobotics.org/index.php?id=home&news_id=264> 2. Department of Foreign Affairs and Trade 2012, Trade At A Glance 2012, <http://www. dfat.gov.au/publications/trade/trade-at-a-glance-2012.pdf> 3. Department of Industry, Innovation, Science, Research and Tertiary Education 2012, Prime Minister’s Manufacturing Taskforce Report of the Non-Government Members, August 2012, <http://www.innovation.gov.au/Industry/Manufacturing/Taskforce/Documents/ SmarterManufacturing.pdf> 4. International Federation of Robotics 2012, Industrial breakthrough with robots, Press release 23 May 2012, <http://www.ifr.org/news/ifr-press-release/industrial-breakthroughwith-robots-381/> 5. Elfes, A 2013, Why the Australian manufacturing industry needs the next generation of robots, The Conversation 6 February 2013, <http://theconversation.edu.au/why-the-australianmanufacturing-industry-needs-the-next-generation-of-robots-11888> 6. ProcessOnline 2012, Dual-arm concept robot, 9 October 2012, <http://www.processonline. com.au/news/56366-Dual-arm-concept-robot> 7. ProcessOnline 2012, Robotic assistants may adapt to humans in the factory, 9 October 2012, <http://www.processonline.com.au/news/56379-Robotic-assistants-may-adapt-tohumans-in-the-factory>

MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

NON-METALLIC DRUM PUMP The portable, non-metallic Flex-I-Liner rotary peristaltic pump from Vanton Pump and Equipment Corp evacuates drums and totes containing acids, caustics, salts, chlorides and reagent grade chemicals, without corrosion of the pump or contamination of the fluid. The self-priming design has no seals to leak or valves to clog, and can run dry for extended periods without damage. Compact in size with

DIGITAL PRESSURE SENSORS

integral handle, it fits on drum lids without pro-

The Ahlborn FDAD33 and FDAD35M high-precision pressure

truding, and has sufficient lift characteristics to

sensors include an integrated A/D converter and signal

operate from the floor, skid or stand.

conditioner. The piezoresistive transducers feature a high level of accuracy, a wide temperature range (-40 to +120°) and digital outputs of measured values. They measure 1 to 1000 bar full scale and maintain 0.05% FS error between -10 and 40°C. The digital high-precision pressure sensors FDAD33/35M are temperature independent and come equipped with the Almemo D6 plug that enables the measurement of transitory pressure fluctuations and pressure peaks by capturing the current values and calculating the maximum value, minimum value and the average value all in the ‘smart’ connector. All calculated output values can be transferred to a PC via USB adapter cable or data can be logged in an Almemo data logger. Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/S743

Only two non-metallic parts contact fluid: a thermoplastic body block and an elastomeric flexible liner that can be replaced in the field without special tools. The rigid body block is of solid polypropylene, UHMW polyethylene, or PTFE, and the moulded flexible liner of natural rubber,

ALL-HYBRID PXI EXPRESS CHASSIS National Instruments has introduced what it claims is the industry’s first all-hybrid PXI Express chassis featuring PCI Express 2.0 x8 links to every slot for increased data throughput resulting in lower test times and reduced cost of test. The hybrid slot connectors deliver maximum flexibility in PXI and PXI Express module slot replacement, while the addition

Neoprene, Buna-N, Hypalon, Viton or Nordel

of hot-swappable fans and an easily

elastomers, eliminating corrosion or contamination

replaceable power supply improves

associated with metal pumps.

system availability in high-performance

A rotor mounted on an eccentric shaft oscillates

applications.

within the flexible liner, imparting a progressive

The chassis expands the reach

squeegee action on the fluid trapped in the

of PXI into more demanding high-

channel between the liner and the body block. Flanges on the flexible liner are pressed to the side of the body block by concentric grooves on the bracket assembly and the cover plate, isolating the fluid to the channel. The pump is suitable for flows from 1.25 to 151 L/h and pressures to 310 kPa at temperatures to 121°C. Acromet (Aust) Pty Ltd Contact info and more items like this at wf.net.au/R950

performance streaming applications such as RF record and playback while preserving backward compatibility with PXI modules released over the past 15 years. The PCI Express 2.0 x8 links to every slot for offer a bandwidth of 4 GBps/slot and 12 GBps for the system. The all-hybrid-slot backplane accommodates both PXI and PXI Express modules, while hot-swappable fans and a toolless, easily replaceable power supply improve total system availability. Remote system health monitoring improves system manageability. National Instruments Australia Contact info and more items like this at wf.net.au/R852

8 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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Another I/O change? Great. So another wiring schedule. Another marshalling design. And another cabinet... Just make it all go away!

YOU CAN DO THAT Electronic marshalling eliminates the rework, the redesign and the headaches. With DeltaV Electronic Marshalling, Emerson lets you make I/O changes where and when you need them without costly engineering and schedule delays. Our new DeltaV CHARacterization Module (CHARM) completely eliminates the cross-wiring from the marshalling panel to the I/O card–regardless of signal type–so you’re no longer held to predefined specifications. All those wires, gone. All that time and engineering, gone. See how easy it can be by scanning the code below or by visiting IOonDemandCalculator.com

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH CONFIGURABLE IPC The Valueline P7000 IPC can be configured as a box PC with various mounting options or as a classic panel PC. Phoenix Contact Pty Ltd

WF.NET.AU/T059

> SHAFT ENCODER TESTER The Encoder Laboratory is designed to test and simulate all aspects of an incremental shaft encoder. Plant Control & Automation

WF.NET.AU/S885

> ULTRASONIC LEVEL CONTROLLER

IS CALIBRATOR

The MC2-IS intrinsically safe multifunction calibrator has a display with an LED back-

The Series UTC ultrasonic liquid transmitter controller provides

light for improved display visibility in various

non-contact measurement of liquid level and open channel flow.

environments.

Dwyer Instruments (Aust) Pty Ltd

AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/S813

WF.NET.AU/S936

10 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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NEW PRODUCTS

PROGRAMMABLE LOGIC CONTROLLERS Rockwell Automation has released the Allen-Bradley Micro850 and enhanced Micro830 PLCs. Both micro PLCs feature embedded motion capabilities for up to three axes of motion, allowing them to support a wide range of applications. The Micro850 micro PLC is equipped with the same form factor, plug-in support, instruction/data size and motion capabilities as the 24-pt and 48-pt Micro830 controllers, but with the added capabilities of ethernet and expansion I/O. The Micro850 controller specifically targets the needs of OEMs and is designed for stand-alone machine applications. The Micro850 controller has an ethernet port for higher performance connectivity to human-machine interfaces (HMIs). The EtherNet/IP protocol with CIP Symbolic support is used for simplified Allen-Bradley PanelView Component HMI connectivity. Tags created while configuring the HMI screens can easily reference the variable names in the Allen-Bradley Micro800 program. With support for up to five plug-ins, OEMs can customise the functionality of the controller with additional I/O, special functions and serial ports without increasing the size of the controller. If more I/O or higherperformance analog I/O is required, the Micro850 controller supports up to four 2085 expansion I/O modules, including high-density digital I/O and high-accuracy analog I/O, for a total of 132 digital I/O points. The Connected Components Workbench software simplifies the installation, configuration, connectivity and maintenance of machine devices, including the series of Micro800 controllers, Allen-Bradley PowerFlex AC drives and PanelView Component graphic terminals. The single software saves OEMs time and associated costs compared with using a different programming tool for each device. Rockwell Automation Australia Contact info and more items like this at wf.net.au/S206

E-STOP PUSH-BUTTON RANGE Pilz has expanded its PITestop range of E-STOP push-buttons, including push-button, contact block with bracket and surface mount housings to make it easier to select the right E-STOP solution. All Pilz push-buttons are now also available in a new design and with quick-connect technology plus an integrated monitoring function. Illuminated mushroom-type push-buttons are suitable in difficult light conditions or for visual indication of activation, push-buttons with keys allow resets to be performed by one person only and devices with a protective collar prevent unintended activation. On the updated E-STOP push-buttons, the E-STOP symbol is on the push-button itself - and due to the clear design, it can also be applied in three places. As a result, there is no need for additional labelling in the operating language. The push-in technology used on the PITestop also allows for rapid assembly and installation work is reduced considerably. All PITestop push-buttons now have a monitored contact block. The monitoring function - an N/O contact connected in series - ensures that the push-button is not rendered inoperable due to external conditions in the machine environment, such as vibration for example, without this being indicated. In the event of an error, the N/O contact breaks the circuit and the malfunction is indicated. Suitable for worldwide use, PITestop meet all the relevant international standards and regulations such as EN/IEC 60947-5-1, EN/IEC 60947-5-5 and EN ISO 13850. Pilz E-STOP push-buttons are designed to satisfy even specific light or hygiene requirements up to protection type IP69k. Pilz Australia Industrial Automation LP Contact info and more items like this at wf.net.au/S409

12 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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NEW PRODUCTS

VIS-NIR SPECTROMETERS The Corona Plus range of sturdy, compact VIS-NIR spectrometers from Carl Zeiss has been specially designed for use under industrial conditions. The systems can be used for the measurement of various optical properties such as reflection, transmission, colour and

VALVE POSITIONERS

coating thickness of transparent samples and coatings,

The Spirax Sarco SP400 and SP500 valve positioners

across a wide range of in-

are claimed to be the most energy-efficient digital

dustries and at every stage

electro-pneumatic valve positioners available, based

of the production process.

on steady state air consumption.

The combination of the lat-

All pneumatic positioners leak some air holding an

est polychromator technolo-

actuator in steady and transient state, and these leak

gies featuring high-quality

rates are stated in positioner technical documentation.

optics and fast, low-noise electronics provides the foundation for maximum

The SP400 and SP500 have recently been certified by

sensitivity, linearity and a high dynamic range. The range is particularly

Lloyds Registry EMEA to have a minimum leak rate

useful for complex, fast measurements in quality and process inspection

of 0.48 dm3/hour, which greatly reduces the cost of

in architectural and automotive glass production or in the plastics, coating

wasted compressed air.

and solar-energy industries.

The SP400 and SP500 are quick and easy to install

The range contains PGS polychromators, enabling higher resolution

and commission, with the latter being complete in three

across the wavelength range. Further benefits include a long service life of

button pushes or less. This simplicity of use minimises

the light sources in the NIR, less noise, good linearity, the use of modern

plant downtime, while non-contact position feedback

communication interfaces and reduced power consumption - which results

technology reduces installation time and provides

in less thermal build-up and therefore higher stability. Most versions are

increased accuracy and reliability over mechanical

offered either as single- or dual-beam systems.

linkages. The SP500 also supports the HART protocol. Spirax Sarco Pty Ltd

Carl Zeiss Pty Ltd Contact info and more items like this at wf.net.au/S844

Contact info and more items like this at wf.net.au/S840

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MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

NEW PRODUCTS

INLINE DENSITY METER The compact and accurate Anton Paar L-dens 427 density meter allows users to upgrade an existing volumetric flow measurement system to mass flow for tanker loading, terminal and batch operations. Users gain the benefits of tanker loading optimisation and maximising batch yield. The Anton Paar L-Dens 427 measures directly inline, without the need of a by-pass line, eliminating cost and reducing risks.

WIRELESS GATEWAY MODULE The Banner Engineering SureCross B2Q Gateway Module has been developed to provide embeddable, dependable and cost-effective communication capabilities for the company’s Q45 wireless sensor network. The module features discrete outputs and DIP switches to map inputs from up to two wireless sensors to the gateway’s outputs. With its board-level design and easy mounting capabilities, the Banner Q45 B2Q gateway is easily embedded inside equipment, enclosures and on control panels. The SureCross B2Q Gateway module initiates communication with the Wireless Q45 sensors and accurately controls timing and configuration for the entire network. DIP switches allow users to select one of eight defined I/O mapping configurations to automatically map the Q45’s inputs to the Gateway’s outputs. The included Site Survey analyses the network’s strength and reliability and conveys results through a bi-colour LED indicator. Transceivers provide bidirectional communication between the Gateway and Q45, including fully acknowledged data transmission, and lost RF links are detected and relevant outputs set to user-defined conditions. The SureCross B2Q Gateway module was developed for use with Banner’s SureCross Q45 wireless sensor family. Designed with a proprietary, self-contained battery, radio and sensor, the SureCross Q45 improves efficiency by monitoring and coordinating multiple machines and processes. Micromax Pty Ltd Contact info and more items like this at wf.net.au/R993

TRANSMITTER SIGNAL CONDITIONERS Acromag’s TT230 series of isolated transmitters are designed to provide easier installation and setup. These signal conditioners are only 12.5 mm wide for high-density mounting on DIN rails and provide a convenient USB connection to a PC for simple, precise configuration using Windows software. A number of models are available to isolate and convert thermocouple, Anton Paar density meters have

RTD, voltage or current input signals to a 4-20 mA output. These

been used for 40 years to pro-

two-wire instruments are loop-powered and support both source

vide high accuracy concentration

or sink output wiring connections on the current loop with a

measurement using density, sound

12-32 VDC supply. A ruggedised design features -40 to

velocity and viscosity measure-

80°C operation, electrical noise immunity and surge

ments. With the release of the

protection.

L-Dens 427 series of density sen-

All units support both 4-20 mA sinking (2-wire) and

sors, it is easy to integrate density

sourcing output (3-wire) device wiring to eliminate con-

measurement in volumetric flow

fusing model selection. Each model accommodates a

systems at an economical price.

variety of signal types. Thermocouple units accept eight

The L-Dens 427 series has a range

different sensor types (J, K, T, R, S, E, B, N), as well as ±100 mV

of communication options to con-

inputs. RTD units accommodate 2-, 3- and 4-wire 100 Ω platinum

nect to a PLC, control system or

sensors or 0-900 Ω linear resistance inputs. Voltage models convert

terminal automation system.

bipolar signals from ±10 mV to ±150 VDC with multiple selectable ranges. The current units are widely adjustable to support ±20 mA,

B-R Controls Pty Ltd Contact info and more items like this at wf.net.au/S528

0-20 mA and 4-20 mA DC input signals. All models deliver high accuracy and noise resistance, and fast response times. They also demonstrate high linearity and stability with very low temperature drift. Software calibration eliminates zero/span pots, DIP switches and push-buttons for easy programming of ranges, over/under-scale thresholds and fail-safe settings. Metromatics Pty Ltd Contact info and more items like this at wf.net.au/S466

14 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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NEW PRODUCTS

SMALL-VOLUME PROVER CONTROLLER Honeywell has launched a major upgrade to its small-volume provers. The Enraf Small Volume Prover (SVP) Controller now allows users to visually monitor and control the operation of the prover in real time on a clear LCD. Small-volume provers are essential technology in the oil and gas industry to verify the accuracy of flow meters that gauge the volume

INTELLIGENT UPS The Quint UPS-IQ mounting rail UPS power supply from Phoenix Contact now also has data communication capabilities to allow it to communicate with higher-level controllers. It provides continuous information about the charging state, remaining run time and lifespan of its energy storage devices, thus maximising system availability. The data cable now allows the UPS module to be integrated directly into the automation application. The information provided by the uninterruptible power supply can, for example, be forwarded to higher-level controllers via ethernet, or integrated directly into the company’s control solutions. The available control logic values allow the system to execute a program routine in the event of certain situations, such as power outages. The UPS’s status data are combined centrally. Automated measures are derived that

of liquids being transferred, for example when loading or unloading ships. The controller’s 6-line LCD displays all critical prover data, including piston position, motor status, error status, cycle value, proving run date and sweep time. A handheld local access device (LAD) allows users to fully program the controller and provides multiple diagnostics, an active and historical alarm log, secure alarm acknowledgement and clearing, and with an option kit, full management of the water draw sequence.

are tailored to the individual system. The data cable has an RS232 interface for Modbus communication that allows integration of the UPS solution into an ethernet network via a COM server. In addition, higher-level controllers such as the inline controller (ILC) or remote field controller (RFC) from the company can be addressed directly. An inline controller can be used as a gateway to facilitate the use of other transfer protocols. Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/S746

A sweep time display in seconds with repeatability in milliseconds provides precise visual reading of the time taken by the piston to travel between upstream and downstream optical switches - vital for pulse-generation calculations and the repeatability of proving runs.

SCADA APP FOR WINDOWS 8

An on-screen cycle counter and customisable

InduSoft has released the InduSoft Visualization App for Windows 8 and Windows

preventative maintenance service alarm improve

RT. As the first SCADA/HMI visualisation app created specifically for Windows 8, the

reliability, and an adjustable delay, to keep the

InduSoft Visualization App offers mobile access to InduSoft Web Studio applications

motor running after the motor stop switch is

from any Windows 8 device. The app enables users to access SCADA information

activated, allows the drive system to position

from a variety of mobile access stations such as phones, tablets and laptops.

the puller bar closer to the piston catch for

InduSoft Visualization App gives users the ability to monitor critical information

the next proving cycle, cutting cycle times.

anytime at their fingertips. Users can view alarms, alarm history, process values,

The SVP is intrinsically safe and, combined

trends and historical data from any location using their Windows 8 operating system.

with flameproof design, has ATEX and CSA

InduSoft offers a demo application for users to take a test drive and experience the connectivity to Windows 8. Dominion Electronics Contact info and more items like this at wf.net.au/S937

16 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

approval for use in hazardous areas. Honeywell Limited Contact info and more items like this at wf.net.au/S135

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Two GreaT Companies. one BriGhT FuTure. How do you create a global company built for the future? By combining two powerful histories in pursuit of a bold vision—to help companies around the world contribute to healthier, safer environments. Building on the achievements of Pentair and Tyco’s Flow Control businesses, comprised of Valves & Controls, Thermal Controls and Water & Environmental Systems, the new Pentair delivers exceptional depth and expertise in filtration and processing, flow management, equipment protection and thermal management. From water to power From energy to construction From food service to residential We’re 30,000 employees strong, combining inventive thinking with disciplined execution to deploy solutions that help better manage and utilize precious resources and ensure operational success for our customers worldwide. Pentair stands ready to solve a full range of residential, commercial, municipal and industrial needs.

pentair.com/valves

NEW PRODUCTS

ETHERNET SWITCHES WITH PROFINET The Moxa EDS-405A and EDS-408A-PN are 5- and 8-port managed ethernet switches with Profinet enabled. With embedded Profinet, the PN switches can be easily integrated into the Simatic Step 7 engineering tool, making it more convenient for automation engineers to configure through Step 7 and monitor with automation HMIs. The EDS-405A/408A-PN switches with fast booting, Turbo Ring and Turbo Chain fast-recovery technology can help to optimise Profinet network performance. Moxaâ&#x20AC;&#x2122;s Profinet switches also support a variety of useful management functions, such as IGMP snooping, IEEE 802.1Q VLAN, QoS, port mirroring, SNMP, bandwidth management and warning by email or relay. The switches are IPv6 Logo Committee certified and also offer DHCP Option 82 for IP address assignment with different policies. They conform to Profinet v2 class B, GSD (General Station Description) v2 and Simatic Step 7 device icons are available. EtherNet/IP and Modbus/TCP protocols for device management and monitoring are also supported. There is a command line interface for quickly configuring major managed function, and port-based VLAN, IEEE 802.1Q VLAN and GVRP are available to ease network planning. Madison Technologies Contact info and more items like this at wf.net.au/S933

TEMPERATURE TRANSMITTER Emerson Process Management has released an enhanced Rosemount 644 temperature transmitter, featuring ease-of-use improvements and a modular design that enables customised functionality at each process point. The Rosemount 644 temperature transmitterâ&#x20AC;&#x2122;s modular components allow users to easily customise its base model to fit any application, so they only purchase what they need and have more to spend on additional measurement points. Human-centred design makes the device easy to wire, with clear, straightforward diagrams and improved accessibility. A simplified transmitter interface and second sensor input help to minimise installation and maintenance time, and increase productivity. Key capabilities now available in the 644 include Hot Backup and Sensor Drift Alert, which ensure seamless performance in the event of a sensor failure, and advance notification of potential issues so users can be proactive and maintain total process control. The enhanced 644 is SIL2 safety certified to meet safety application requirements and users receive full documentation for easy SIS compliance. Its Local Operator Interface (LOI) option provides a cost-effective and convenient solution for on-the-spot commissioning and in-field configuration. With its straightforward menu structure, users have immediate access to the information they need to troubleshoot issues, validate measurements or make adjustments to ensure efficiency and reliability. Emerson Process Management Contact info and more items like this at wf.net.au/S389

18 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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NEW PRODUCTS

M12 JUNCTION BOX Turck has introduced a 6-port M12 passive junction box that is designed to easily integrate multiple devices into a single unit. Featuring a compact, lowprofile design, the 6-port model allows

MACHINE-MOUNTABLE REMOTE DISPLAY

simple installation in diverse factory

Banner Engineering has added the Machine-Mountable Remote

automation applications, ranging from

Display to its line of iVu vision products. The device enables users

packaging and automotive to materials

to view the iVu sensor image remotely and serves as a constant

handling and mobile equipment.

monitoring and user programming interface, without interference from electrical noise.

With one or two discrete signals per port, the 6-port junction box is capable of providing up to 12 discrete

The device features a metal housing to shield the display from

signals, ensuring reliable connectivity for multiple devices. The junction

electrical noise, while its cabled connector provides a secure, depend-

box consolidates several discrete devices in an area to one device, which

able connection. The rugged, noise-immune, stationary remote display

is then connected to a controller via a single cable. This eliminates each

features an 89 mm colour, flat-panel touch screen LCD with a wide

device requiring its own individual cable, delivering a more cost-effective,

viewing angle of 60° left and 60° right; 50° up, and 55° down. Two

streamlined connectivity solution.

LEDs on the remote display provide feedback of the remote sensor

The 6-port model provides 2 A of current per signal and up to 9 A

operation - one for power/error, and the other indicating inspection

total current per junction box. For durable performance, the M12 pas-

pass/fail. It is available in five cordset lengths, ordered separately.

sive junction box features IP67-rated ingress protection and operates in

Mounting brackets and a stylus are included with the cordset kit.

temperatures ranging from -40 to +85°C.

Micromax Pty Ltd

Turck Australia Pty Ltd

Contact info and more items like this at wf.net.au/T009

Contact info and more items like this at wf.net.au/T002

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MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 19

CHOICES IN AUTOMATED LEVEL DETECTION Glenn Johnson, Editor

PART 2

In part 1 of this article we looked at the challenges associated with level measurement and at a few of the common point level detection technologies available. In this part we move on to overview continuous level measurement technologies.

s explained in Part 1, there are many level measuring situations in which virtually any measuring technology will work, but there are also many cases where some technologies will work while most others will not. Continuous level instruments come in many forms and can be applied in various ways, both intrusively and non-intrusively. In many cases they will cost more than point level instruments, due to their relative complexity, but as stated previously, they can also be used for point level detection, the advantage being that with some technologies they can provide point level detection without contacting the medium.

Floats The simplest form of level measurement is with a float or displacer, a device that rides on the surface of the material within the vessel. The float must have a lower density than the material and be made of a material that will not react with it. There are two common ways a float level is usually measured automatically. The first is a float in a sight glass or bridle at the side of the tank. The float may be magnetic so then its position

20 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

can then be detected magnetically. The other is to use a wire and spring-loaded pulley system that maintains the tension on the wire - the wire reel then uses a multiturn potentiometer, rotary encoder or digital instrument to measure the depth by the angular position of the reel. Both these methods only work for liquids, but may not be appropriate if the density of the liquid is likely to change, since they are dependent on the buoyancy of the liquid and must be calibrated to a particular buoyancy. The wire float method can be employed for solids, but must use a more complicated method of lowering a weight until it rests on the surface, and lifting it out again when the tension changes, because leaving the float on the surface may result in it getting buried, rather than ‘floating’. An example of just such a device for silos is shown in Figure 1.

Hydrostatic pressure (head measurement) A vertical column of fluid exerts a pressure due to the column’s weight. The relationship between column height and fluid pressure at the bottom of the column is constant for any particular

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Level detection

vessel by connecting the ‘high’ port to the vessel and leaving the ‘low’ port open to the atmosphere. Given that the vessel is open to the atmosphere, the level will be directly proportional to the pressure at the bottom of the vessel (the differential pressure between the two ports, or between the vessel bottom and the atmosphere). It should be noted that typically the instrument may not be mounted at the bottom, but may be physically located above or below the vessel bottom, and connected via an ‘impulse tube’ or capillary. If this is the case, the difference in height between the instrument and the measurement point will create an error equal to the height difference, increasing the level reading if the instrument is lower and decreasing the reading if the instrument is higher - an error that must therefore be compensated when calibrating the instrument. In the case of a closed vessel, vapour trapped above the liquid will exert additional pressure on the liquid. In this case the DP instrument cannot use atmospheric pressure as the ‘reference’. Typically in this case, the ‘low’ port is connected to the space at the top of the vessel, so that the vapour pressure is compensated for. There are various additional factors that need to be taken into account when using DP instruments for level measurement, and that depends on the application. These factors are beyond the scope of this overview article.

Submersible pressure sensors

fluid (density) regardless of vessel width or shape. This principle makes it possible to infer the height of liquid in a vessel by measuring the pressure generated at the bottom. For a given liquid density, the pressure measurement can be calibrated as a depth measurement. The critically important factor is that one must accurately know the liquid’s density in order to calculate the liquid’s level using hydrostatic pressure. Having an accurate assessment of liquid density also implies that density must remain relatively constant despite other changes in the process, so using hydrostatic pressure to measure level is suitable for a single liquid of known and constant density. Density of the liquid may also change with temperature variation, so in this case it may be necessary to compensate for temperature variation.

Differential pressure transmitters Differential pressure (DP) transmitters are the most commonly used instrument for this type of measurement. They are designed to provide a calibrated output based on the difference in pressure between two ports (a ‘high’ port and a ‘low’ port). The simplest application is measuring the pressure at the bottom of an open

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In open air applications, where the sensor cannot be mounted to the bottom of the vessel (such as in an outdoor reservoir), a direct hydrostatic pressure level sensor can be suspended from a cable into the tank to the bottom point that is to be measured. The sensor must be specially designed to seal the electronics from the liquid environment. In tanks with a small head pressure, it is very important to vent the back of the sensor gauge to atmospheric pressure, otherwise normal changes in atmospheric pressure will introduce large error in the sensor output signal. In addition, most sensors need to be compensated for temperature changes in the fluid.

Air bubblers An air bubbler system uses a tube with an opening below the surface of the liquid level. A fixed flow of air is passed through the tube. Pressure in the tube is proportional to the depth (and density) of the liquid over the outlet of the tube. A DP transmitter can therefore be connected to the bubbler tube to measure the pressure in the tube relative to the atmosphere. Air bubbler systems contain no moving parts, making them suitable for measuring the level of sewage, drainage water, sewage sludge or water with large quantities of suspended solids. The only part of the sensor that contacts the liquid is a bubble tube, and since the point of measurement has no electri-

MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

Level detection

Type

Continuous level detection for liquids

Servo/float

Continuous level detection for solids

Interface detection

Yes

Electromechanical

Yes

Capacitance

Yes

Hydrostatic pressure

Yes

Differential pressure

Yes

Ultrasonic

Yes

Continuous radar

Yes

Guided wave radar

Yes

Radiometric

Yes

Table 1: Summary of continuous level instrument applications.

cal components, the technique is a good choice for hazardous areas - the control portion of the system can be located safely away at a distance. The main disadvantages of bubblers are that like the DP level technology, their calibration is affected by changes in product density, and that they are not suitable for closed (non-vented) vessels.

Capacitance level instruments Capacitance level sensors can be used with a wide variety of solids, liquids and slurries. The sensors can be designed to sense material with dielectric constants as low as 1.1, such as coke or fly ash, and can also be used in a wide range of liquid applications. These instruments work by the same principle as the point level capacitance sensor mentioned in Part 1 of this article. As the level rises, the air or gas normally surrounding the electrode is replaced by material having a different dielectric constant. The resulting change in the capacitance results in a proportional level measurement. The probe should be grounded when used with non-metallic vessels. If there is a chance of coating on the probe, then the related RF admittance technology should be used, because the admittance sensor, by taking into account both the conductance and susceptance of the material, can compensate for the effect of coatings on the probe.

Ultrasonic level instruments Ultrasonic level instruments use a piezoelectric transducer to generate a sound wave to be reflected off the contents of the vessel. The device measures the length of time it takes for the reflected sound wave to return to the transducer. The main advantages of ultrasonic level instruments is that they are a non-contact technology with no moving parts and a single top of vessel entry makes leaks less probable than fully wetted techniques. They are useful for both liquids and solids, and since they are non-electromagnetic, they work independently of the dielectric constant of the material. They are often used in open, atmospheric tank water applications. Powders, heavy

22 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

vapours, surface turbulence, foam and ambient noise can all affect the returning signal, however, and ultrasonic devices will not operate in vacuum or high-pressure applications. Obstructions in the vessel can also create problems for these types of instruments.

Radar level instruments Radar level instruments operate on a principle similar to ultrasonic instruments except that the signal is a microwave RF signal, and as such they depend on detecting the difference between the dielectric constant of the material to be measured, and that of the space above it.

Free air radar With free air radar two types of signal are used - frequency modulated continuous wave (FMCW) and pulsed time domain reflectometry (TDR or ‘time of flight’). TDR instruments emit a burst of microwave energy and the antenna then acts as a receiver to receive the pulse reflected from the surface of the material. Level is calculated from the time of flight of the signal echo back to the instrument (how far the pulse travelled from the top of the vessel). FMCW systems in contrast emit a continuous swept frequency signal and distance is inferred by the difference in frequency between the transmitted and received signal at any point in time (since the material will alter the signal). This method is more expensive than TDR measurement but also more accurate. Radar level instruments are highly accurate in large storage tanks and some process vessels, and can be used for continuous level measurement of both solids and liquids. In the case of pulsed radar there needs to be sufficient empty space at the top of the tank, as these instruments lose accuracy when the surface to be measured is too close to the instrument, or if the vessel has radar-reflective obstructions such as ladders and agitators that may be ‘seen’ by the radar.

Guided wave radar A probe or wave guide is inserted into the vessel through a tank nozzle. Pulses of microwave energy are transmitted down the probe and reflected back. This has the advantage that

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Level detection

Figure 1: Electromechanical level measuring device for solids (Endress+Hauser). Figure 3: A submersible pressure sensor (Turck).

Figure 2: DP level transmitter with diaphragms for mounting in the vessel, connected via impulse tubes (Vega).

the probe ‘guides’ the RF signal and can therefore be placed clear of obstructions. It also means that the RF energy can be guided below the surface of the material, which is useful for interface detection - two pluses will be reflected back with different times of flight, indicating both the top surface and the interface. Guided-wave radar instruments can be installed in stilling wells to replace existing mechanical gauges or capacitance probes. They may not be suitable for some solid level measurement, however, due to the risk of damage to the probe. For interface detection, the dielectric constant of the lower material must be higher than the dielectric constant of the upper material, and they are more susceptible to errors if a vapour exists above the liquid, since the vapour’s dielectric constant will be the same as, or similar to, the liquid being measured.

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Nucleonic measurement Nucleonic level instruments can be used for both point and continuous level measurement, and are usually deployed where penetration of the vessel is undesirable, such as in conditions of extreme temperature or pressure, or where the material to be measured is highly toxic or corrosive. Radioisotopes are used to emit gamma radiation that passes through the vessel wall and process material. A scintillation detector on the other side of the vessel detects the radiation passing through and infers the level. Nucleonic measurement, however, has a high cost of ownership. There are hidden costs associated with safe handling and training, as well as initial licensing and periodic inspection by external authorities or the supplier, and when they are no longer required, the nucleonic instrument must be disposed of through appropriately licensed, external organisations. As such, nucleonic measurement is often seen as an expensive ‘option of last resort’ for special cases.

MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

NEW PRODUCTS

INDUSTRIAL PCS The Neousys range of industrial fanless embedded PCs for industrial automation, vision and measurement applications is now available nationally from Madison Technologies.

SCADA SYSTEM UPDATE

The Neousys range of industrial PCs includes the

ABB has released the latest version of its Supervisory Control and Data Acquisition

Nuvo-1000 Series multiple GbE platforms, Nuvo-2000

system, SCADAvantage version 5.4. This release is designed to help oil and gas

Series fanless IPC with expansion slots and the

companies manage their operational challenges with precise liquid metering and

Nuvo-1300af fanless GbE embedded controller.

instant status checks of remote operations, and to bring better safety and availability to companies responsible for the critical energy infrastructure. SCADAvantage now supports V-cone and liquid measurement data. This data is integrated with alarming, trending and historian information to further optimise operations and manage by exception. ABB also worked with midstream companies to develop a new liquid volume balancing and leak detection application in this release, to better support safe and reliable liquids transportation. ABB SCADAvantage includes features to ensure business continuity providing protection against threats from the environment,

The Neousys Nuvo-1000 Intel Core i7/i5 fanless

malicious attacks and other sources. Disaster Recovery works in warm-standby for

platforms are designed for multiple-camera applica-

ultra-fast failover and includes tools for configuring and stepping through a recovery

tions such as city surveillance, machine vision, medical

scenario in a safe yet expedited manner.

imaging and automation control. Up to five Intel 82574L

This release also includes Geographic Information System (GIS) mapping capabili-

GbE controllers offer high video stream performance.

ties. Using the latest mapping software from ESRI, SCADAvantage allows companies

The Neousys Nuvo-2000 Intel Atom D525 fanless PC

to easily customise the map views to meet their operational needs.

is a compact controller with the flexibility to expand

With on-demand text message reporting, operators can be alerted and follow up on

one or three PCI/PCIe slots. Nuvo-2000 accommodates

issues or drill down into the data easily with a simple text message on their mobile

up to three PCI/PCIe cards and two 2.5â&#x20AC;ł hard drives

phone. Text reports can also be requested from SCADAvantage by sending a text

in its shoe-box size. It also provides versatile I/O

message with a particular report identifier.

interfaces such as COM ports, USB ports, a gigabit

Version 5.4 is available now and is provided as part of ABBâ&#x20AC;&#x2122;s annual software

ethernet port, a parallel port and mini-PCIe port, and

maintenance program.

isolated DIO channels can be integrated optionally.

ABB Australia Pty Ltd

The Neousys Nuvo-1300af is a fanless embedded

Contact info and more items like this at wf.net.au/S760

controller with integrated gigabit PoE ports. Incorporating an Intel Core i7 processor, the Nuvo-1300af controller offers high performance for arithmetic-intensive

OPTICAL DISTANCE SENSOR

applications, while its fanless design provides reliability

Even with extraneous light of up to

and durability.

100,000 lux the ifm efector O1D series

Madison Technologies

optical distance sensor provides reliable

Contact info and more items like this at wf.net.au/S463

performance. The sensor detects all distances, even in direct sunlight, irrespective of whether the target is fully exposed to the light or only the sensor, or both. Even reflective and shiny polished metal surfaces of stainless steel or aluminium are claimed to be reliably detected. The company claims the sensor is insensitive to reflective surfaces such as reflective strips on safety vests or reflectors and can be used in outdoor applications for position monitoring such as portal lifters on loading stations. As well as the optical distance detection of up to 10 m range, this product has two switching outputs, one of which can be set as an analog output. The detection zone is scalable and has a window function. The sensor can also be used in applications with background suppression. ifm efector pty ltd Contact info and more items like this at wf.net.au/S362

24 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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NEW PRODUCTS

FORMULATION SOFTWARE Mettler Toledoâ&#x20AC;&#x2122;s networked software solution, FormWeigh.Net, is designed to put users in control of the formulation process through the elimination of human errors, cost optimisation, compliance, and an increase in quality, consistency and efficiency. The software ensures the formulation process delivers stable product quality. Tailored to match operations, it can automate, streamline and simplify complex formulation routines. With the software, bad batches are eliminated through the use of systematic quality checks. The software ensures expired or quarantined materials are not used by accident in the weigh and dispense process, and operators are guided through accurate weighing with easy to understand dialogs and colour displays. Security features such as barcode verification scans help ensure full compliance and traceability is achieved automatically. All information, including recipe details, order data and executed work steps, are stored in a centralised database and can be retrieved at any time for monitoring and reporting. FormWeigh.Net is flexible and scalable to a userâ&#x20AC;&#x2122;s needs. It operates on standard PCs as well as industrial scale terminals which are suitable for washdown or hygienic manufacturing areas. When used in regulated industries such as pharmaceutical or nutraceutical production, the software can be enhanced to achieve full regulatory compliance. Complete validation documentation developed according to GAMP5 guidelines is also available. If needed, the software can also be linked to ERP systems for exchange of order and stock data.

CONFIGURABLE RFID READERS Turck is expanding its range of RFID handheld devices with software that can be specifically tailored to the requirements of individual users. This offers a complete solution, which, in addition to the special handheld device, includes a customised user interface, RFID tags and also stationary read/write heads if required. Write and read commands can be executed via the touch screen or keypad. The read information can be shown on the display according to customer requirements. The handheld readers are available for both HF and UHF systems and can also read barcodes or data matrix codes as well as RFID tags. The handhelds can communicate with mobile devices, PCs or other systems via Bluetooth, WLAN or a standard USB cable. The recorded data can be fed into an ERP system, for example, and linked with the data of an existing database. Alternatively, users can also develop their own software solutions using the software developer kit.

Mettler Toledo

Turck Australia Pty Ltd

Contact info and more items like this at wf.net.au/S850

Contact info and more items like this at wf.net.au/S831

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MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

NEW PRODUCTS

TANK LEVEL ALARM SYSTEM The API Industry TLA-500 tank level alarm system provides safety during loading and storage of liquids. The level alarm is IECEx certified intrinsically safe and is also designed to meet all International Maritime Organisation requirements for tankers. The TLA is designed specifically for operations in liquids and liquefied gases and special versions are available for extremely harsh and difficult environments, including versions for arctic/antarctic ambient temperatures and LNG gas carriers. It is available to customer specifications and is thus suitable both as standalone on the replacement market or as part of a complete API TSS/Cargo control system. Control levels are set at the upper level (95%) and at emergency level (98%) of the tanks. If these control levels are reached during loading, the API TLA sets off an alarm together with an indication of the level reached. Being built on patented acoustic wave technology, the TLA ensures the accuracy of measurement regardless of shape of tank, type of liquid or product temperature. The TLA is installed externally, with only the metal rods inside the tank. Acoustic waves are created by piezoelectric energy in the metal rods. When the liquid in the tank reaches the probe on the rods, the emission of sound waves is attenuated. This change is detected by the piezoelectric unit and signals are transmitted to the corresponding alarms. With only the metal rods inside the tank and no mechanical or moving parts, no routine maintenance is required on the unit. Zedflo Australia Contact info and more items like this at wf.net.au/S896

REMOTE ACCESS SOLUTION Secomea has expanded the range of 3G SiteManager units to include CAPS

PLUGS

COVERS

MASKING

models 1439 and 3439 with four LAN ethernet ports. Out of the box, these LAN ports operate as a 4-port switch. Alternatively, they can each connect to a different physical network to provide access to large distributed installations. The SiteManager is a front-end interface for monitoring multiple industrial devices on a location. Working with GateManager authentication server and a LinkManager client, it ensures secure access to remote devices over the internet. A redundant WAN connection on 3G models helps provide uninterrupted access. The solution provides an easy to configure and use method for remote access. While many remote access solutions rely on using a computer as the site interface, the Secomea approach provides direct access to PLCs, drives and other programmable units, with the client’s own PC hosting the application software from anywhere in the world as though they were physically connected. SiteManager

Nobody has a greater range of Flexible Vinyl Caps and Plugs than STOCKCAP. And they’re in stock now for immediate delivery. Ideal to protect, mask or insulate components from shipping, storage or processing damage, STOCKCAP Flexible Vinyl Caps and Plugs fit snug to seal out moisture, oil and dirt. Choose from thousands of sizes, shapes and colours all at the industry’s most competitive prices. So if you need Caps or Plugs in stock, get ours ex-stock. FOR FREE SAMPLES AND A CATALOGUE CALL Sinclair & Rush Pty Limited 51 Wellington Street Riverstone NSW 2765 info@sinclair-rush.com.au Fax: (02) 9627 5156 Tel: (02) 9627 3211

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is also equipped with USB and serial ports to accommodate virtually all configurable equipment. The remote access solution is used by major machine builders and system integrators all over the world, with the highest security for both the remote client and the site. The product is well suited to end users who need to remotely access equipment for monitoring status or perform corrective actions. Security features include two-factor authentication login and AES/ SSL encryption on all connections, providing the highest confidence. Daanet Pty Ltd Contact info and more items like this at wf.net.au/S839

26 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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How to connect robot cells to any industrial network Svensk Industriautomation (SVIA) is a fast-growing automation company in Jönköping, Sweden, developing robot systems for customers in the Nordic countries, Germany, UK, the Netherlands and the US. The systems they put together are robot cells which are able to communicate with other systems in a factory. The core of the robot cell is SVIA’s own vision system called Pickvision, which detects exactly how a particular object is placed on a conveyor belt and thereby enables a robot to pick up the object. In simple terms, you could say that SVIA enables robots to see. This technology has become very popular on the automation market and has enabled SVIA to double its turnover during the past few years. “Our strength lies in the simplicity,” says Anders Mandorsson, Designer and Project Manager at SVIA. “It is very easy to tell the robot what to pick from the carrier belt, and then you are ready to go.” By using the Pickvision software, users take a picture of the object which is to be picked from the belt. The software automatically detects the shape of the object and every time this shape shows up in the camera, the robot is able to determine how to pick it up. As with most advanced automation systems, SVIA’s robot cells need to communicate with some kind of plant-wide industrial network and this type of communication is not always hassle-free. “A couple of years ago, we built a robot cell for a customer who promised me access to their Profibus system; but after a while, it became clear that our system was only to be a separate node in their network. That’s when we found Anybus X-gateways from HMS. We tried installing one into our cabinet and it handled the conversion between our DeviceNetbased system and the customer’s Profibus system in a very elegant way,” says Mandorsson.

28 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

Since then, SVIA has used Anybus X-gateways in many of the robot cells they deliver to customers around the world. Once again, simplicity is key. “DeviceNet is the standard we use in most of our cabinets and instead of handling the conversion to other networks ourselves, we simply install an X-gateway from HMS. It is cheaper, but above all, it makes it easier for the customer since he gets a clear segregation between our system and his own factory network,” he said. SVIA’s robot cells usually come with robots from ABB which operate on a DeviceNet-based network. The robots can easily communicate with another DeviceNet network, but if they are to be connected to another network, for example a Profibus or an EtherCAT network, a ‘translator’ is needed. Anybus X-gateways handle the conversion between the two networks through built-in software which restructures the data from one side and makes it understandable on the other side. The configuration is made in a matter of minutes by using the Anybus Configuration Manager software, which means that no programming is necessary. SVIA’s robot cells are flexible and can be adjusted to cater for different customer applications such as mounting, packaging, drilling and lathing. Through Anybus X-gateways, SVIA can also be very flexible when it comes to the network they can connect to. “To be honest, we don’t really think much about networking anymore,” says Mandorsson. “When we create a robot system, we simply order the X-gateway which converts to the customer’s industrial network - we plug it in and it works.” Global Automation Asia-Pacific Contact info and more items like this at wf.net.au/T001

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NEW PRODUCTS

RTU PROGRAMMING ENVIRONMENT HMI DEVICES

CSE-Semaphore has released TWinSoft Suite version 11 for its TBox

The TP 5000 Series

remote terminal unit (RTU) products.

HMI range from Phoenix

TWinSoft 11 provides a menu-driven environment for programming in

Contact is powered by

IEC 61131-3 Ladder Diagram as well as function blocks and Basic. In

the high-performance Intel

addition, TWinSoft Suite includes TWinSoft Automation, which is an envi-

Atom 1.6 GHz CPU. The Visu+ runtime

ronment that allows users to interact with such Microsoft applications as

software is available on three different displays for visualisation:

Excel and Visual Basic rather than process automation languages. Via

30.73 cm (12.1”), 38.1 cm (15”) and 43.2 cm (17”).

simple, menu interactions, TWinSoft allows users to rapidly configure the

The integrated OPC server or additional ethernet-based drivers

IP, web and telemetry technology platform in TBox RTU products. This

are used to link to the control level, and Profinet is also supported.

technology features an integral web server and push technology via email,

This offers advantages such as IP allocation via the engineering

FTP and SMS text messaging.

station or PLC for commissioning, connection monitoring for

The key update provided in version 11 is the company’s WebForm Studio

operating tasks, as well as location identification functionality for

2.0. With WebForm Studio 2.0, users can build live process displays that

service and support.

are compatible across all web-enabled devices including smartphones,

Interfaces available include two ethernet ports, four USB ports and RS 232, as well as a VGA interface. Multistation operation

tablets and PCs. All information in a TBox - alarms, live information, and historical data - is available to PC and mobile device users anywhere. The company’s configuration environment incorporates Asynchronous

can be set up by connecting an external monitor. These devices are suitable for large machines and plants where

JavaScript and XML (AJAX), the agnostic technology of reference for

HMI SCADA functionality is required. They also have a high-quality

Web 2.0 and scalable vector graphics (SVG). No programming or device-

aluminium housing that is dust protected and water resistant at

specific apps are required. With WebForm Studio 2.0, there is no required

the front in accordance with IP65.

software licensing.

Phoenix Contact Pty Ltd

CSE-Semaphore Pty Ltd

Contact info and more items like this at wf.net.au/S271

Contact info and more items like this at wf.net.au/S400

IMPAC INFRARED TEMPERATURE SENSORS Small, economically priced short wavelength digital infrared Thermometer with fiber optics for non-contact temperature measurement between 100 &1200 Deg. C.

■ Small housing dimensions for easy installation suitable for use in confined spaces

IGA 320/23-LO

■ RS485 interface for long transmission networks for connection to a PC via USB converter or machine control (PLC) ■ Analog output adjustable to 0 or 4 to 20 mA for connection of standard analyzing instruments ■ Internal digital signal processing for high accuracy and long temperature ranges ■ High quality optics for measurement of small objects ■ Built-in LED targeting light for easy alignment to the measuring object ■ Applications include forging, induction heating, welding and hardening

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MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

NEW PRODUCTS

PRODUCT QUALITY VALIDATION SOFTWARE ATS International has released an updated version of its product quality validation software. Version 19 of CM4D provides

VISUAL IR THERMOMETER

enhanced performance capabilities that will allow users to

The Fluke VT02 Visual IR Thermometer is a troubleshooting camera

retrieve inspection data, generate critical quality reports, analyse

with an infrared heat map. It is designed to fill the gap between

production problems and prevent build issues more efficiently.

single-point infrared thermometers and high-resolution thermal

Among the enhanced features, users will benefit from the 64-bit

imagers, for when a single-spot temperature reading isnâ&#x20AC;&#x2122;t enough

architecture and CrypKey licensing.

and a high-resolution thermal image is more than users need. One

ATS CM4D is now available as a 64-bit application. This will

tool combines the visual insight of a thermal imager, the visual

allow the software to use modern 64-bit operating systems

images of a digital camera, and the point-and-shoot convenience

to their full potential, both in processing power and memory

of an IR thermometer.

utilisation. Although the web-based applications are not 100%

Conducting inspections for electrical, industrial, HVAC/R and

64-bit, users will still benefit from the improved performance

automotive applications is faster with the camera than an infrared

of the 64-bit services and the CM4D client that is run by the

thermometer, which requires multiple readings and manually recorded

web services. The product is also available as a 32-bit applica-

results. The camera instantly detects problems using blended thermal

tion for users with 32-bit operating systems. As of version 19,

and digital imagery. It will display and save images as full visual, full

CrypKey licensing will replace FlexLM and previous versions

infrared, or in three blended modes (25, 50, and 75 per cent). Markers

of CrypKey licences. All upgrades to v19 will require a new

pinpoint hot and cold spots indicating the hottest temperature with a

licence, but if a current SMA is in place, a new licence (with

red box and the coldest with a blue box. A temperature reading is

the same features as the current licence) will be included with

provided at the centre point. Images are saved to the micro-SD card,

the upgrade. If users are upgrading to v19 from a previous

eliminating the need to write down single or multiple measurements.

version, they will need to perform a one-time migration of all

Images from the camera can be imported into the included SmartView analysis

existing DataSmith translators, DataSmith Batch settings and

and reporting software, to produce professional reports that document problems

database passwords. The necessary migration tools are included

detected or repairs made for management and customer review.

with the v19 installation packages.

Fluke Australia Pty Ltd

ATS Applied Tech Systems

Contact info and more items like this at wf.net.au/S982

Contact info and more items like this at wf.net.au/S451

30 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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NEW PRODUCTS

PORTABLE SAMPLE CONDITIONING Without sample conditioning the results of moisture measurements may be affected by pressure, while sensors are at risk of damage by particles, liquids or glycol in the sample gas. Michell Instruments has produced compact and light sample systems to ensure that making spot checks of moisture with a portable hygrometer will give readings that are as reliable as online measurements. The MDM300 sample panel is a fully functioning portable sample system that provides both flow control and filtration, but is also compact and light enough to carry. The sample panel is capable of measuring moisture in gases under pressure - up to 300 barg - and will operate in temperatures up to +50Â°C. Further sampling options and accessories for the MDM300 range are available including kits with sample pump, SF6 application kits and a medical gas kit for clean air in hospitals. The companyâ&#x20AC;&#x2122;s Easi-fit and Compressed Air Kits are suitable for applications where the sample is above atmospheric pressure. The Compressed Air Kit includes a particulate filter and fittings to make it easy to connect into a compressed air system. The kits are small, making them a convenient method to ensure correct measurements from common applications for the MDM300. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/S843

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MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

NEW PRODUCTS

MODULAR CALIBRATION SYSTEM Beamex has introduced a modular calibration system, the MCS200. It is a test and calibration system for workshops and laboratories. ESD protected, the MCS200 offers a safe and ergonomic solution for the calibration and maintenance of process instruments. The workstation enables calibration of pressure, temperature, electrical signals, frequency and pulses; testing of electrical and electronic devices; soldering and de-soldering of traditional and surface-mounted components; as well as the testing of electric motors and other electrical devices. As a single calibration workstation or complete workshop, the MCS200 offers time savings and efficiency. Fully automated pressure calibration can be performed, communicating with the company’s POC6 Automatic Pressure Controller. Fully automated temperature calibration is also available, using Beamex FB and MB temperature blocks. Documentation of calibration tasks can also be automated, due to seamless integration with the Beamex CMX calibration software. HART, Foundation fieldbus and Profibus PA instruments can be calibrated on the workstation without being connected to the bus. Carrying out calibrations with the workstation is claimed to offer many advantages. All equipment is panel mounted and always ready for use, and high pressures can be conveniently regulated from the workstation without the need to operate with hydraulic hand pumps or DWTs. Fully automated calibration and documentation is possible, both for conventional and for HART and fieldbus instruments. There is no need for separate storage or charging of equipment after use. N M W1 3 A D 1 0 . p d f Pa ge 1 1 2 / 0 2 / 1 3 , 2 : 2 2 PM AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/S842

Making Manufacturing • Explore the latest in manufacturing innovation • Enhance efficiency and boost productivity

• Exchange ideas on critical industry issues • Network and do business face-to-face

12 dedicated product zones. Over 300 exhibitors. New Sustainable Manufacturing zone.

MELBOURNE CONVENTION AND EXHIBITION CENTRE

32 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

7-10 MAY 2013

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NEW PRODUCTS

COMPACT CORIOLIS MASS FLOW METER The Rotamass LR Coriolis mass flow meter is designed to measure both liquids and gases. The effective turndown of the flowmeter is no less than 2000:1 for liquids and 5000:1 for gases and the mass flow measurement range spans from 1.5 g/h to 40 kg/h, achieving a measurement accuracy of ±0.15% for liquids and ±0.5% for gases. The flowmeter’s dual bent tube optimally decouples the core measuring element from process vibration that can cause fluctuating zero stability and decrease measurement accuracy. When fluid density changes, a single-tube Coriolis flowmeter can become unbalanced and start to behave like an emitter. The Rotamass LR remains balanced due to the equal mass change in both tubes and the absence of interference from the process piping. By design, it is insensitive to fluctuations in the ambient temperature and achieves good zero stability under changing process conditions. The two tubes are made from C-22 alloy, which is less susceptible to thermal expansion than conventional stainless steel. Normally it is more difficult to measure temperature with Coriolis flowmeters that have tubes with a smaller surface area. The Rotamass LR uses an inline temperature sensor, ensuring precise and fast measurements in process temperatures ranging from -50 to +150°C. The flowmeter has a gas-tight, all-stainless-steel secondary containment that can handle pressures up to 65 bar. It can be used in high-pressure applications up to 400 bar. The flowmeter does not use gaskets, minimising the risk of leaks. Insulation and a heat jacket are available as options. Yokogawa Australia Pty Ltd Contact info and more items like this at wf.net.au/S846

RUGGEDISED WIRELESS EQUIPMENT Acksys offers a wide range of ruggedised wireless equipment for industrial and transportation applications using the Wi-Fi IEEE 802.11 a/b/g/n standard in 2.4 and 5 GHz bands. The range of products addresses the specific issues associated with operating wireless equipment in vehicles. The devices have a tough die-cast aluminium construction, are temperature hardened for -40 to +70°C operation and environmentally sealed to IP66. Lightning/surge protection is built in, and they operate from a very wide power supply voltage - typically +9 to +70 VDC. A unique feature of the system is the removable ‘C-Key’ which stores all configuration data and allows instant equipment swap-out and data-restore functionality. The system includes point-to-point, point-to-multipoint and wireless mesh technologies and is suitable for long-range line-of-sight and non-line-of-sight operation. Applications include access points, bridges, bridge routers, repeaters, and serial-to-wireless gateways. The company provides integration into industrial and vehicle systems with the capability to interface to truck telemetry and fleet management systems; stream data from rolling stock to station; wirelessly connect RS232, RS422, RS485 serial equipment together; build a wireless bridge between a serial Modbus network and Modbus/TCP; and wirelessly connect ethernet, Modbus/TCP, Profinet, Ethernet/IP and DNP3 equipment. Madison Technologies Contact info and more items like this at wf.net.au/S462

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MARCH 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

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

THE TRUTH ABOUT COMPRESSED AIR AUDITS

egardless of the brand or type of equipment that you currently use on site, the expectation is that any company providing compressed air auditing services would provide a well-rounded and unbiased set of recommendations. While simply typing ‘compressed air audits’ into Google will show an endless list of providers, it is important to exercise caution when choosing a company. Air audits are routinely provided for free by several companies that are directly involved with the sale of compressed air equipment. Audits are often considered to be ‘sales tools’ that push companies towards specific outcomes. The majority of auditors have either equipment that they hope to sell or existing equipment on the site to protect. In such situations, the best interests of the client may not be a priority. Be aware that dealing with an OEM company that also provides audits carries a set of risks. There is a chance that you could get a biased report that is far from being a well-considered, independent outcome for you as the client - it wastes considerable capital on an ill-fitting solution with a payback that may never be achieved. What can’t be measured can’t be improved! Reliance on inadequate or inaccurate data often has very costly and long-lasting implications and consequences. To achieve meaningful recommendations, appropriate parameters (power, pressure and flow) need to be analysed at the right frequency - 1-second data intervals are best, with anything more than 5 seconds potentially creating misleading results. There are important questions to ask of every audit. Does the audit consider pressure and flow variability? Will it consider how the compressor’s performance changes with system demands? Does it cover all areas of your compressed air system? And, most importantly, is your audit report more than just a bunch of lines on a piece of paper? Smoke and mirrors can often cloud reality, with providers hiding behind a veil of uncertainty. Auditors need to be able

ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

to properly demonstrate how the results of an audit can lead to the recommendation, and completely justify the scale of savings. Some project-based solutions might include major system redesigns or repairs and possibly recommend new or alternative compressor technologies. New compressors are not a ‘magic pill’ that will cure all of the ills of a flawed compressed air system design. Technologies such as variable speed drives, two-stage compression, air treatment and advanced system controllers may be some of the many recommended. Variable speed drives might be suitable for some applications but certainly not for every company’s needs. A VSD compressor could actually cost more to run than a simple fixed speed solution in some situations. Only after a very detailed review of your entire system’s supply and demand profile will you gain a clear picture of how air is consumed and how efficiently it is generated and distributed to the point of use. If you’re considering a compressed air audit, it is recommended that you choose a company with a strict adherence to an independent approach. This will provide for a neutral, unbiased and commercially impartial recommendation and ultimately provide the best compressed air solution for your site.

Quentin St Baker is the National Manager for the Energy Efficiency S er vi c es di vi s i on a t CA PS A u s t ra li a . H e has extensive experience in the compressed air industry and has pr o vi d e d a s s i s t a n c e to many well-known organisations to identif y and implement energy-efficiency solutions. Representing CAPS on the Energy Efficiency Council, Quentin is a mechanical engineer who has undertaken extensive training to make him one of Australia’s leading specialists in the science of compressed air.

34 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2013

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Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP255003/00198 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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