What’s New in Process Technology Jul 2014

July 2014 vol.28 no.2 PP100007403

July 2014 vol.28 no.2 PP100 00740 3

0714

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY JULY 2014

CONTENTS 4

sing Ethernet technology to U optimise PLC networks

This month we’re celebrating the introduction of EtherNet/IP communications and ladder logic to the Pilz PSS 4000 - a move that will make it even easier to manage automation tasks.

The EtherNet/IP communications capability and the ability to now program the PSS 4000 in ladder

8

New Products

12

Hot products online

automation market to increase usability and

20

tandardised technologies for S secure real-time drilling data

Users can now select three of the five program-

logic was specifically targeted at the Australian functionality. ming languages from the international standard IEC61131-3 - Function Block diagram, Instruction

38

As I see it

List and Ladder Diagram, providing a higher level

Customise or compromise

of usability and flexibility.

All the programming languages can be combined with the innovative PASmulti editor to simplify the design of complex programs - a feature unique to the Pilz model.

The Pilz safety and standard control system can communicate with the common systems via Modbus TCP, Profibus-DP and EtherNet/IP natively, and utilising the additional gateway modules CANopen and EtherCat. The PSS 4000 is versatile enough to be used as either a combined standard and safety PLC or as a standalone safety PLC. Coupled with the PASmulti editor, the PAS4000 Ladder Diagram editor makes setting up a safety PLC system a breeze.

PSS 4000 has been successfully implemented in solutions for manufacturing, food and beverage, mining, oil and gas, rail, building management and amusement rides.

Pilz Australia Industrial Automation LP www.pilz.com.au

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

http://www.processonline.com.au/latest_issues

Scan the QR code to find out more about the automation system PSS 4000 or visit www.pilz.com.au (and enter webcode 5092).

USING ETHERNET TECHNOLOGY TO

OPTIMISE PLC NETWORKS Gary Chang Product Manager, and Mark Wu Technical Writer, Moxa Inc

4 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

www.ProcessOnline.com.au

T

he term automation was introduced in 19461, later published in a magazine in 1948 and defined as “the art of applying mechanical devices to…perform these tasks in timed sequence…under pushbutton control at strategic stations”. What engineers had in mind in the 1940s remains fundamentally the same as what control engineers intend to achieve today with automation: minimising human involvement while maximising output capacity, increasing production speed and ensuring consistent repeatability. Until recently, automation systems were isolated and generally consisted of I/O devices connected directly to PLCs, which in turn connected to SCADA systems in local control rooms. Today, a major difference exists in the architecture of modern industrial automation networks - in the form of a technology that is increasingly being deployed to connect large-scale distributed systems with remote monitoring and control centres. That technology is Industrial Ethernet.

Industrial Ethernet technology consists of various Ethernet-based protocols, developed with deterministic capabilities, as robust alternatives to costly proprietary automation systems. More importantly, they enable a highly scalable and unified infrastructure to converge all network nodes at the administrative, control and field levels. Many advanced industrial automation systems utilise gateways to efficiently bridge fieldbus I/O devices to Ethernetbased PLCs, and Ethernet switches to connect PLCs and SCADA terminals at remote control centres, reducing operating costs and improving production efficiency by expanding automation networks.

According to recent studies conducted

by IMS Research, three of the most pervasive Ethernet-based protocols, EtherNet/ IP, Profinet and Modbus TCP, account for more than 65% of the world’s existing industrial automation deployments, and their collective growth from 2010 to 2015 is expected to exceed 18 million new nodes.

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However, the worldwide number of existing fieldbus devices (all protocols) will increase from 183 million in 2010 to over 326 million by 2015. This steady growth, despite the increasing popularity of Industrial Ethernet, is primarily due to the fact that fieldbuses are still considered to be the easier, and more cost-effective, protocols to deploy at field-level networks than Industrial Ethernet. Another contributing factor is that there are exponentially more nodes in field-level networks than nodes in control- or supervisory-level networks.

As growing industrial automation networks expand to increase productivity, and factory systems converge for centralised control, the integration of various Ethernet-based protocols and bridging of fieldbus systems will be inevitable.

An Ethernet-based single-network infrastructure offers operators the efficiency of centralised network management with greater network scalability and flexibility, higher bandwidth availability and faster failure recovery. To optimise system performance and improve network manageability, switches and gateways should integrate seamlessly with industrial automation networks for centralised control and monitoring. However, integrating industrial fieldbus with Industrial Ethernet presents integrators and engineers with two considerable challenges: • Centralised monitoring of all network nodes, including switches, should be available on control and SCADA systems. However, standard Industrial Ethernet switches do not process industrial automation protocols and therefore are unable to be monitored on the same control system as the PLC and other I/O devices.

• Existing fieldbus devices can account for a substantial portion of a company’s assets, and their integration with Industrial Ethernet networks can be done via PLC modules. However, for large-scale control systems, deploying Industrial Ethernet gateways would be a

JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

© Giuseppe Porzani/Dollar Photo Club

Traditional fieldbus networks were - and some still are - isolated automation systems that required extensive local monitoring and routine on-site maintenance. To increase productivity and reduce operating costs, many manufacturers and plant operators have deployed Industrial Ethernet to converge remotely isolated fieldbus systems for centralised control and monitoring.

Field Level

Control Level

Management Level

Industrial ethernet

Figure 1: Worldwide market share by protocol. (Source: IMC Research 2011)

more cost-effective solution to integrate fieldbus devices, but a substantial amount of time can be required to manually configure the switches and gateways.

Many manufacturers offer switches and gateways to integrate fieldbus-to-Ethernet communication for automation systems consolidation, with emphasis on device features and system interoperability between components and PLCs. But these are just the basic requirements of systems convergence. Most industrial switches and gateways available today are designed only with automation-centric perspectives. The optimisation of the PLC network, such as overall performance, configuration/management efficiency and application flexibility, seems to have been overlooked.

Components for PLC network optimisation As device networks expand into larger control networks through fieldbus-toEthernet integration, network deployment and management become more complex, and network performance becomes highly critical. To optimise PLC network performance and management, Industrial Ethernet switches and gateways should be designed with a network-centric approach to enhance overall performance, improve configuration efficiency, simplify network management and provide application flexibility.

High performance ensures high network capability Performance optimisation of industrial automation networks is critical for maximum productivity and reliability. High bandwidth,

Figure 2: Ethernet at the control level.

high data transmission rates, switch ASICs and hardware features are indispensable components of high network performance.

However, these factors are useless if the network is unavailable. Maintaining high network availability not only requires reliable network devices, but also speedy recovery of the network and its components during maintenance or in the event of a connection or device failure.

Industrial Ethernet switches High-speed redundancy Redundancy is a must-have component to ensure industrial automation reliability.

Prolonged periods of unplanned system downtime can jeopardise on-site personnel safety, severely impact plant productivity and possibly damage expensive factory equipment and machinery. Recent refinements in redundancy technologies not only provide millisecond-level network recovery, they can also substantially reduce the costs of deployment.

Faster-than-PLC power cycling Power cycling of switches and PLCs is generally required for plant-wide maintenance updates. Most managed switches can take approximately three minutes, if not more, to reboot because they have relatively low processing power. PLCs, on the other hand, operate by using simple ladder logic, and power cycling normally takes less than one minute. Administrative-level nodes (such as SCADA and HMI) will have no access to control-level and device-level nodes until switches have completed POST (power-on self-test) diagnostics and the bootstrap loading process. The difference between the duration of power cycling times of PLCs and

6 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

switches will not only delay maintenance efforts, it can even cause port lockouts in some older time-sensitive automation systems. Advanced managed switches are now capable of completing a power cycle in the 10-second range.

Industrial Ethernet gateways Processing power Typical gateways have access to 16-bit processing power, which limits the gateway to eight simultaneous connections and delays response times. Newly developed 32-bit Industrial Ethernet gateways can handle up to 16 concurrent connections (from SCADA/ HMI/PLC) without compromising response time or transmission reliability.

Data prioritisation Most switches already offer packet prioritisation between administrative-level (SCADA/ HMI) and control-level (PLC) devices. Some Ethernet gateways are now also capable of providing device-level (fieldbus I/O) data prioritisation to enhance QoS (quality of service) and improve determinism.

The core of industrial automation consists of SCADA, PLC and I/O devices. Switches and gateways enable fieldbus-to-Ethernet convergence by providing network communication between these core devices at field, control and supervisory-level networks.

For performance optimisation of large-scale industrial automation networks, it is imperative that each network component operates with timely efficiency.

Advanced efficiency simplifies configuration and monitoring Efficiency of switch and gateway configuration during fieldbus-to-Ethernet integration

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Industrial ethernet

has previously been reliant on the expertise of system integrators. Gateway configuration can be extremely time-consuming as it requires manual input and is verified through trial and error. In addition, the isochronous nature of hard real-time industrial automation systems does not tolerate delays and requires precise calibration of critical parameters, such as gateway response time-out settings, to prevent system errors. Furthermore, optimising PLC network management requires tools for network configuration and monitoring, not only to ensure reliable operation and immediate event notification, but also to provide effortless maintenance updates to minimise system downtime.

Industrial Ethernet switches Plug-and-play simplicity Switches deployed on the factory network should also be enabled with Industrial Ethernet protocols such as Profinet, Modbus TCP, and EtherNet/IP. This allows switches to be integrated into the SCADA/HMI of industrial automation systems for optimised consolidation of network configuration, management and control without the need for additional configuration or modifications.

Device parameters and monitoring In addition to relay output warnings for on-site network performance monitoring, switch parameters, such as power, port and redundancy statuses, should also be accessible by SCADA systems. Switch visibility in SCADA systems is vital to maintain healthy PLC networks, and access to device parameter allows remote monitoring of switch components, providing operators complete control-level network information.

Industrial Ethernet gateways Intelligent auto-detection The latest innovations in Ethernet gateways can eliminate the tedious tasks of fieldbus parameter input and device configurations, which, even for experienced systems integrators, can be extremely complex and timeconsuming. Recent gateway developments enable fieldbus-to-Ethernet integration in a fraction of the time by automatically detecting Profibus I/O modules and Modbus device settings to eliminate the possibility of manual input errors.

Monitoring and diagnostic tools When network communication errors halt production lines on the factory floor, control engineers must quickly locate and resolve the root cause. When problems occur, gateways should be equipped with relay output warnings to immediately trigger an alarm at the control room or a shutoff

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RECENT REFINEMENTS IN REDUNDANCY TECHNOLOGIES NOT ONLY PROVIDE MILLISECOND-LEVEL NETWORK RECOVERY, THEY CAN ALSO SUBSTANTIALLY REDUCE THE COSTS OF DEPLOYMENT.

mechanism on the factory segment to minimise the impact of a system failure. Many intelligent gateways also offer software diagnostic tools to assist control engineers in troubleshooting. When communication errors are determined to be the root cause of a system failure, engineers can quickly access gateway data transmission logs and filter out erroneous fieldbus frames for review and analysis.

Manual input of I/O modules and device time-out settings can take many hours, if not days, to complete. More intelligent switches and gateways can assist system integrators and control engineers to effortlessly deploy, configure and update industrial automation segments within the network to quickly enable production on the factory floor.

Maximum flexibility to converge various applications Industrial automation network infrastructures can span across multiple plants in multiple remote locations, where various applications are performed in various industrial environments. Switch and gateway flexibility allows operators to optimise PLC network deployments with devices that are best suited for applications in industries such as chemical plants, wastewater treatment and oil refineries.

Industrial automation networks will require different types of gateways and switches for different applications. These applications can require different port densities and various combinations of port types, such as fibre, PoE, SFP ports with Fast Ethernet, Gigabit or 10GbE connectivity. Furthermore, industrial automation applications, whether indoors or outdoors, can present some of the most challenging conditions, pushing devices to their limits.

Environmental factors such as extreme temperatures, vibration, shock, corrosion, dust, moisture, humidity, power surges and EMI will require the deployment of industrial-grade devices with industry-specific certifications and compliance. Listed below are a few types of application-specific requirements.

• Wide-temperature operation is necessary for many outdoor environments, where temperatures can dip well below -30°C at night and rise to well over 70°C in the daytime.

• Gigabit PoE can be deployed to combine control-level communication with video surveillance of the factory floor, eliminating the need for external power cabling.

• Fibre is a media commonly used to provide long-distance communication between remote networks. Also, EMI immunity makes fibre the choice for many power industry applications.

• 10GbE and layer 3 switching are required in control rooms with largescale surveillance systems to provide the data rates required for HD-quality video transmission.

• M12 connectors are required for severe outdoor applications, such as mining and transportation industries, where intense vibration and dust can compromise network communication.

• Ingress protection (IP) is important for application environments where contaminants and high humidity can cause device malfunction and even failures.

Many vendors offer a selection of switches and gateways specifically designed for a targeted application, without much consideration of how these devices can impact the automation network as a whole. Consequently, operators can be left with a multivendor network that does not work as a cohesive whole and can severely impact overall network performance and manageability. Converging various systems and applications within the PLC network requires a wide spectrum of switches and gateways, not only designed and calibrated specifically for each application to provide maximum deployment flexibility, but also to optimise the configuration, performance and reliability of PLC networks as a whole.

References 1. Pursell C, 2008, A Companion to American Technology, Blackwell Publishing Madison Technologies www.madisontech.com

JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

ENTRY-LEVEL HMIS Siemens has expanded its range of operator devices for simple applications. The 4“ to 12“ second-generation Simatic HMI Basic Panels are claimed to offer an innovative user experience with ease of servicing and high-resolution wide-screen displays with up to 64,000 colours.

The devices are suitable for getting started with graphical process visualisation. With their numerous integrated software functions, such as a reporting system, recipe management, curve functionality and language switching, users benefit from improved visualisation and process quality even when they are running simple applications. Process monitoring is simplified by an integrated USB interface. The operating options can be expanded by connecting a mouse, keyboard, or bar-code scanner as required.

Projects created for a basic panel, can be easily transferred and migrated to devices of different performance classes or display sizes. This allows users to respond quickly to changing requirements. Various controllers can be connected using the integrated Profinet or Profibus DP interfaces. Configuring the Simatic HMI basic panels in TIA Portal enables the user to achieve a higher level of engineering efficiency.

Siemens Ltd www.siemens.com.au

PANEL PCS Axiomtek has announced the 15.6″ WXGA GOT3157W111-PCT and 18.5″ WXGA GOT3187W-111-PCT fanless

AMD A50M FCH chipset. Both industrial-grade touch

MULTIVARIABLE VORTEX FLOW METERS

panel PCs are equipped with 16:9 aspect ratio WXGA

The vortex multivariable flow

colour TFT-LCD with a modularised design. The fanless

meters from Azbil North America

yet noiseless design, wide temperature range (-10 to

employ three sensing elements in a

+45°C) and waterproof enclosure (IP65 front bezel)

single meter: a vortex shedding veloc-

ensure reliable operation in extreme environments.

ity sensor, an RTD temperature sensor

multitouch panel computers. The units support the lowconsumption AMD G series T56N processor with the

The GOT3157W-111-PCT and GOT3187W-111-PCT

and a solid-state pressure transducer.

provide PCI Express Mini Card slots and a WLAN

Within this single instrument, users

antenna for wireless network connections. The touch

can measure the mass flow rates of

panel system support one DDR3 SO-DIMM slot with

gases, liquids and steam with far

up to 4 GB memory and feature one 2.5" SATA HDD

more accuracy than with external

and CompactFlash socket. Other I/O features include

measurement techniques which

two COM ports (one RS232 an one RS232/422/485),

may not adequately compensate

four USB 2.0 ports, two Gigabit Ethernet ports, an

for dynamic process conditions.

audio (line-out) port, and a VGA connector. They units

With the flexibility to install in

equipped with various mounting options: panel mount,

almost any location - including hot

wall mount, VESA arm and desktop stand.

tapping - users can get precise measurements from

Braemac Pty Ltd

nearly any location when needed.

www.braemac.com.au

Multivariable capability within this single housing can also simplify systems, reduce equipment cost and ease installation and maintenance. The wide variety of options and configurations available ensures that there is a meter for any application requirement.

AMS Instrumentation & Calibration Pty Ltd www.ams-ic.com.au

8 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

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Safely Monitor Pressure in Hazardous Areas with the Rosemount® Wireless Pressure Gauge Do you have limited labour resources?

Struggling to add new measurement points?

Lacking the visibility of your process to improve plant operations?

The Rosemount Wireless Pressure Gauge allows you to efficiently see process conditions and gather data reliably and safely. With accuracy rated at Grade 4A of ASME B40.7 and a power module life of 5 years, you have a solution to achieve accurate and reliable measurements in hazardous areas. *Intrinsically Safe for Class 1, Division 1 – Groups A, B, C, D* www.emersonprocess.com.au emersonprocess.australia@emerson.com

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2014 Emerson Electric Co.

NEW PRODUCTS

SAFETY CONTROLLER The Banner Engineering SC26-2 programmable safety controller is used for PLC-level capability and control without the programming complexity and steep learning curve of traditional PLCs. Designed to be more flexible and easier to use than other small footprint safety controllers, the device uses safety function blocks, Boolean logic functions and a user-friendly programming environment for creating safety control logic.

With 26 input terminals and two redundant solid-state safety outputs, safety system design engineers are able to easily monitor a variety of input devices, such as e-stop buttons, rope pulls, interlock switches, safety light curtains and other safety and non-safety input devices.

The safety controller has eight input terminals that can be configured to monitor input device signals, source 24 VDC or serve as IO status outputs.

The optional LCD displays I/O status and actionable diagnostics such as input fault information and device wiring details. This assists users during commissioning and enables faster troubleshooting to minimise machine downtime.

Ethernet models are also available and have an embedded ethernet node that provides up to 64 virtual status outputs. The ethernet I/O registers automatically populate based on the configuration and can also be pared down or customised depending on application requirements. For larger scale applications, Banner will have expandable models in the future, which will allow users to add up to eight additional I/O modules.

Micromax Pty Ltd www.micromaxsa.com.au

SPINDLE CABLE The CF270.UL.D single-core bending-resistant cable, made of fine strands, has been developed for flexible operation in energy chains used in machine tools. This is a spacesaving alternative to the usual space-consuming four-wire servo cables for such applications.

Spindle drives are becoming larger and more efficient in case of machining centres and machine tools. To guide such higher-energy streams, larger conductor cross-sections are required. The consequence is that servo cables are becoming thicker and thicker so that the radius of the energy chain goes beyond the permissible space of the machine tool.

The shielded single-core cable from igus has been de-

MINIATURE INFRARED CAMERA

signed as a spindle cable, meaning it is much thinner and

The latest Micro-Epsilon miniature infrared camera, the TIM450,

suitable for use in an energy chain with a small radius in

offers a high optical resolution of 382 x 288 pixels and features

a machine tool.

a detector able to identify the smallest of temperature changes,

In accordance with the requirements for energy chains,

due to the camera’s high thermal sensitivity (40 or 80 mK). It is

the outer jacket is made of an adhesion-poor PUR mate-

therefore suitable for very small objects which cannot be detected

rial making it oil resistant and notch resistant, as well as

using common cameras.

halogen free and usable in deep-temperature applications.

The cameras are available in four versions, with temperature

The spindle cable CF270.UL.D is available in six different

ranges from -20 up to 1500°C. Key features include a 7.5 to 13 µm

conductor nominal cross-sections, outside diameters and

spectral range, 13°, 38° or 62° FOV exchangeable lenses, and

copper numbers.

80 Hz real-time image recording.

Treotham Automation Pty Ltd www.treotham.com.au

The TIM450 is light, robust and small, and can be powered

by USB. It can also be supplied with a special cooling jacket for particularly demanding applications. Using a blowing-out system and water cooling, the camera is able to withstand ambient temperatures up to 180°C, or 240°C with the 200/230 model.

Bestech Australia Pty Ltd www.bestech.com.au

10 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

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HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

>

PRESSURE TRANSMITTERS

>

HYDAC’s electronic pressure transmitters HDA 4000

HIGH-AVAILABILITY MANAGED SWITCHES

and HDA 7000, and electronic pressure switch EDS 3000, are available with a flush membrane.

The 7000 series managed switches are equipped with the

HYDAC International

CIP protocol and support the Device Level Ring (DLR)

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redundancy mechanism.

Phoenix Contact Pty Ltd http://bit.ly/1lDIVJ2

>

EMBEDDED AUTOMATION COMPUTER

The UNO-2362G automation computer offers an AMD G-series dual core processor, daisy chain network capabilities and Advantech’s iDoor technology.

Advantech Australia Pty Ltd http://bit.ly/1m20uS1

PHOTOELECTRIC SENSOR

>

The TranspaTect is a reflectorless multitask photoelectric sensor with a pinpoint LED as its light source and a switching distance from 0 to 700 mm.

Sick Pty Ltd http://bit.ly/1pOu2FH

12 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

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CASE STUDY

Snack manufacturer increases production with new compressors Kolak Snack Foods is a London snack food manufacturer that, having experienced an upturn in business, needed to increase its output capacity. An upgrade of its production equipment was therefore necessary, and this included its air compressors.

Kolak had several important requirements for its new compressors. It required reliability, continuity of output and no risk of contamination during process operations. To achieve this, Kolak chose to replace its existing units with Atlas Copco oil-free, rotary screw machines.

The company installed two ZT 90 FF compressors and a ZT 90 VSD FF, which provide a guaranteed supply of high-quality air. The ZT 90 FF and ZT 90 VSD FF units are 90 kW air-cooled compressors in which no oil is used in any of the mechanism that comes in contact with the air. As a result of the installation, the process air at Kolak’s London plant complies with the ISO 8573-1 (2010) CLASS 0 standard of air purity, which embraces the Class 0 industry standard. Class 0 measures all three forms of oil contamination: aerosol, vapour and liquid. The compressors supplied by Atlas Copco have been TÜV-certified for zero oil contamination.

In order to meet production demand, the plant operates 24 hours a day, seven days a week, meaning that energy efficiency was also an essential consideration in the selection of new compressors.

“The Atlas Copco VSD compressor works in tandem with the base load compressors to cover all the main 7 bar plant air application duties, including heat exchanger, steam boiler and packing operations. This ensures that output is matched to demand in the most energy-efficient way, with the VSD compressor taking over any additional site load,” said Rikin Lakhani, Kolak’s director.

Each of the Atlas Copco compressors is a fully featured, total installation package - a pre-wired and pre-piped solution, ready for use out of the box. According to Atlas Copco, integrating the compressor’s IMD dryer and its variable speed drive enables the compact package to supply high-quality dry compressed air at the lowest cost.

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The IMD adsorption dryer eliminates moisture before it enters the air net to ensure a reliable process and contamination-free end product. No external energy is required to dry the air and, as the dryer needs no purge air, no compressed air is wasted. The pressure drop through the dryer is minimal, which also reduces the operating cost.

Each of the Atlas-Copco compressors is also capable of providing a clean hot water supply from its cooling system, which can be used for other purposes, such as pre-heated boiler feed water or space heating, further reducing the life cycle cost if required.

Kolak also entered into a 10-year Total Care agreement with Atlas Copco for compressor system maintenance and servicing.

Atlas Copco undertakes responsibility for monitoring and maintaining the installation’s performance.

“We invested in the best possible service package in order to make us futureproof,” Rikin said.

Atlas Copco Compressors Australia www.atlascopco.com.au

JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

NEW PRODUCTS

CONTINUOUS OIL CONDITION MONITORING The LDP100 optical particle monitor measures the degree of cleanliness or the level of contamination in fluids. Compatible media are mineral oils, ester oils and biodegradable oils.

The illuminated back of the LCD display indicates the oil cleanliness level and is divided into sections that show the level of 4, 6, 14 and 21 micron particles within the sample.

The LDP100 operates on a principle of light extinction. The changes to the intensity of a laser beam caused by particles in the medium flowing through the measurement cell are detected by a photodetector. The calibration is made in accordance with ISO11943. If desired, the sample can also be monitored to SAE standards with a press of a button.

On the fluid side, the LDP100 is equipped with two quick-action Minimess connections allowing the unit to be mounted in the oil circuit. The unit is compact and can even be installed on the high-pressure side of a hydraulic powerpack being rated to 420 bar.

Electrically, a stepped analog output shows the value of all levels of cleanliness with an additional solid-state output that can be set to any alarm level. Additionally, there is a full CAN output which enables history and various data to be extracted and displayed. An optional colour LED display can also be fully programmed to display this information remotely, eg, in a control room or a cabin. The electrical connection is installed using a highly waterproof 8-pole M12-plug. ifm efector pty ltd www.ifmefector.com

FIXED GAS DETECTION The Scott Safety Meridian universal fixed gas detection transmitter system supports a full range of toxic and combustible gas sensors, including Scott Safety standard and Rock Solid electrochemical, catalytic bead, infrared and metal-oxide semiconductor sensors.

A single unit can support up to three sensors per transmitter, detecting more than 50 toxic and combustible gases, with each sensor offering its own 4-20 mA output.

The detector’s intrinsically safe, plug-and-play design allows hot-swap sensor replacements without the need to power down the detector or declassify a work area during sensor replacement. This simplifies maintenance and allows sites to maintain production uptime while providing a safe working environment.

The system features a modular design with universal accessories that streamline installation and maintenance tasks as well as ‘futureproofing’ the detector by allowing all future sensor technologies from Scott Safety to integrate into the system. The modular design also provides the flexibility to support industry-standard communication protocols and incorporate new communication protocols as they emerge.

The unit has global regulatory approvals and SIL 2 certification from TÜV-Rheinland.

Scott Safety www.scottsafety.com

14 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

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NEW PRODUCTS

TUBULAR CABLE CONVEYORS Flexicon is offering its Flexi-Disc line of tubular cable conveyors for fragile materials, integrated with upstream and/or downstream equipment that sources material from single or multiple locations and delivers it selectively to storage vessels, filling machines or other processing equipment.

The conveyor moves material using high-strength polymer discs in 10 and 15 cm diameters that are affixed to a stainless steel or galvanised cable. The discs glide within smooth stainless steel tubing, moving fragile products gently, quietly and dust free, horizontally, vertically or at any angle, through small holes in walls or ceilings. The system can have single or multiple inlets and outlets, and convey over short distances or hundreds of metres.

Gentle handling offered by the conveyor makes it suitable for food products that are prone to breakage or degradation including: cereals, coffees, teas, dried fruits, frozen vegetables, grains, nuts, beans, peas, pet foods, seeds, snack foods and spices. Typical non-food applications include bulk chemicals, minerals, chopped fibreglass, microspheres, regrind, pellets, tobacco and other friable materials.

Modular system components of 304 or 316 stainless steel include tubing, drive-wheel housings, tension wheel housings, metered and non-metered inlets, and discharges with and without valves, as well as accessories for wet or dry cleaning, including CIP sanitising.

Free testing is offered at Flexicon test laboratories on full-scale tubular cable conveyors and upstream equipment that simulate customer processes.

Flexicon Corporation (Australia) Pty Limited www.flexicon.com.au

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JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 15

NEW PRODUCTS

FAIL-SAFE VALVE ACTUATORS The Rotork ManPower range provides high-integrity, fail-safe valve operation without the need for any external power supply. The selfcontained system is suitable for workshop or field mounting on a wide range of rotary and linear operated valves and dampers. It offers a cost-effective solution for actuator applications where operation is infrequent. Typical applications include emergency shutdown valves and over- or under-pressure protection at remote, unpowered locations.

Each module contains a compact manually operated hydraulic power unit that provides hydraulic pressure to operate a spring-return actuator. The fail-safe system can be controlled by electrical control signals, pressure pilots or fire sensors. When tripped, the actuator spring cartridge drives the valve to its fail-safe position.

The safe and easy-to-operate system is manually recharged via the hand pump. There are four power-module variants. The company installs the appropriate model on an actuator sized to meet the end-user’s valve torque demand. Modular construction from standard components facilitates quick delivery and simplifies installation, operation and maintenance. Configurations are available for virtually any size or type of valve.

The range is easy to mount on either new or existing valve actuators or dampers. The closed-loop, non-breathing hydraulic circuit is temperature compensated for use in extreme environments. It is also compatible with approved food-grade hydraulic fluids. Installation costs are reduced because the need for plant air, fuel gas, electricity or expensive nitrogen backup systems is eliminated.

Rotork Australia www.rotork.com

ZIGBEE RTD INPUT MODULE The ICP DAS ZT-2015 ZigBee input module offers six RTD input channels, each of which can be connected to different kinds of sensors.

The device features automatic compensation for 3-wire RTDs, with long-distance measurement capabilities so that it can measure accurately regardless of the length of the wires.

Additionally, the module is fully RoHS compliant and has qualification for 4 kV ESD protection as well as 3000 VDC intra-module isolation. Users can easily configure the module address, protocol, checksum, ZB-PID, ZB-channel and type code settings using a combination of rotary and DIP switches.

The DIN-rail mounting module features an ISM 2.4 GHz operating frequency, fully compliant with 2.4 G/ZigBee specifications, with a wireless transmission range up to 700 m. Channels can be individually configured and offer both open wire detection and overvoltage protection.

ICP Electronics Australia Pty Ltd www.icp-australia.com.au

INDUSTRIAL PCS The Designline Series 7000 industrial PCs feature IP65 protection, LED technology, multitouch operation, and displays from 15 to 21.5″.

Equipped with fourth-generation Intel Core i7 processors, they are particularly suitable for tasks which are very demanding in terms of resources in machine control, process visualisation, quality assurance or data acquisition. The integrated Intel HD Graphics 5000 and support for DirectX 11, OpenGL 4.0, and OpenCL 1.2 provide a powerful platform for graphics-intensive visualisations.

Due to the solid die-cast aluminium housing and a device depth of just 60 mm, the industrial PCs are particularly suitable for use directly in machinery. The low current consumption and fanless design ensure energy-efficient, durable, and easy-to-maintain operation and monitoring. With a VESA 100 bracket and a service hatch on the rear, installation and service time can be reduced to a minimum.

Phoenix Contact Pty Ltd www.phoenixcontact.com.au

16 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

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CASE STUDY

Cleaner water in NE Victoria with help from SEW Recent major upgrades to water treatment plants in North East Victoria mean residents can now enjoy cleaner, better tasting drinking water flowing from their taps.

The recent opening of the $5.2 million Corryong water treatment plant - near the upper reaches of the Murray River in the Australian Alps - provides a major improvement to the quality of water for Corryong and Cudgewa residents, while the opening of Whitfield’s $2.2 million water treatment plant in October 2012 marked a new beginning for a town which previously endured regular water restrictions, water carting and boil water notices.

Jack Timmins, process engineer with Laurie Curran Water, explained that his co m p a n y i s a p ro c e s s engineering firm specialising in the design and construction of water and wastewater treatment facilities, and is well known throughout Australia for its expertise in the dissolved air flotation and filtration (DAFF) process.

“For the Corryong water treatment plant project we were contracted by the local water authority, North East Water, to design and construct a 3.2 ML/d DAFF water treatment plant for potable water for the towns of Corryong and Cudgewa.

“We used SEW-Eurodrive geared motors on our vertical inline flocculators. The system required two sets of heavy-duty filters, with four flocculators, with each one driven by an SEW geared motor.

We also used an SEW-Eurodrive geared motor on a thickening mechanism for the washwater treatment,” said Timmins.

Timmins explained that flocculation is widely employed in the purification of drinking water as well as sewage treatment, stormwater treatment and treatment of other industrial wastewater streams.

“During flocculation, gentle mixing accelerates the rate of particle collision, and the destabilised particles are further aggregated and enmeshed into larger precipitates.”

He said flocculation is affected by several parameters, including mixing speeds, mixing intensity and mixing time.

He explained that they used SEW’s geared motors with MOVIMOT integrated frequency inverters on all five projects.

“We like to use a decentralised motor control system as opposed to having it in the central computer. This allows us to walk up and adjust the speed of the flocculators while looking down into the system. By using a decentralised system, we can physically see the rotation of the flocculators instead of walking down, looking at the computer, then walking up again, adjusting the flocculator and back to the computer until we got it right.”

Timmins explained that each filter is about 5 m high, and would normally need two people to set the flocculators up; one telling the other what is going on.

18 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

“And it was the same for the sludge thickening system, with its 3.3 m high thickener vessel. By using a decentralised system, we are able to fine-tune the system so that the speed of the flocculators and thickeners matches the speed that we use in our jar testing. As well as accuracy of the settings, using a decentralised system eliminates the need for a control house mounting of the VSD and the associated wiring and set-up,” he said.

“We have been very pleased with the products, the service and the advice we get from SEW; making sure the most applicable equipment/model is used.

“We worked closely with them regarding torque levels and to ensure the geared motors were not over- or undersized, and that we had the right configuration; the right output shaft to suit our standard paddle design.

“We use a computer-based Citect system to basically start and stop the systems, but the speed control is done integrally using the MOVIMOT drives.

“This allows us to optimise the system through our process, to allow for the ever-changing quality of the water. The MOVIMOT drives give us the flexibility to adjust the system.”

Timmins said the Corryong water treatment plant project also included a dual water treatment module for the treatment of raw water drawn from the Hamilton Hill reservoir, chemical dosing systems for aluminium, caustic soda, polyelectrolyte and gaseous chlorine, a 300 kL washwater tank to accept filtered washwater and DAF float, and a 2.5 kL sludge storage tank.

However, he said the Whitfield water treatment plant, in Victoria’s King Valley wine region, was a little different.

“As well as being smaller at just 150 kL/d with two flocculators, this plant used a mechanical float-off removal mechanism instead of a sludge thickener.

“We only needed three MOVIMOT drives on the Whitfield water treatment plant. But while it’s a much smaller site, we went through the same design issues with SEW, especially on the mechanical float-off removal mechanism,” Timmins said.

Major components of the Whitfield water treatment plant included a 300 kL raw water tank, which accepts water from the King River pump station, chemical dosing systems for caustic soda, aluminium chlorohydrate and sodium hypochlorite, a 235 kL clear water tank, and 25 kL washwater tank and a 15 kL sludge storage tank.

He went on to say that both water treatment plant projects had been very successful, and the residents in the areas are now enjoying cleaner, better tasting drinking water flowing from their taps.

SEW-Eurodrive Pty Ltd www.sew-eurodrive.com.au

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NEW PRODUCTS

PROCESS ACQUISITION CONTROLLER Emerson Process Management has released an updated version of its Daniel process acquisition controller. New features in DanPac Version v3.0 build on the system’s ability to reduce measurement uncertainty, facilitate remote monitoring and control high-precision oil and gas custody transfer and fiscal metering systems.

Key features in version 3.0 include the CalPac metering software suite which comprises a number of applications developed to automate flow measurement calculations and data processing, including gas and liquid calculations, measurement uncertainty and meter factor trending. Integrated historical system performance and process trending capabilities enable operators and management to monitor the metering system. Operators can identify potential meter problems before they can adversely impact system performance. The applications allow automated online validation of metering data in accordance with industry standards, including API, ISO and AGA, to minimise errors and satisfy audit trail requirements.

The DanPac v3.0 release also includes a web-based reporting application to enhance accessibility and audit traceability. The platform also provides secure and encrypted PDF reporting capabilities. These eliminate the possibility of data manipulation and safeguard the integrity of custody transfer and fiscal metering transactions. Users can also customise reporting content and layout to fit their needs.

The DanPac solution is available in four system configurations to ensure a cost-effective solution regardless of the size of the metering operation. The architecture of DanPac v3.0 includes a logic controller and the Daniel S600+ flow computers, and is designed to be redundant for high reliability.

Emerson Process Management www.ap.emersonprocess.com

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JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 19

STANDARDISED TECHNOLOGIES FOR SECURE REAL-TIME DRILLING DATA Gregory Hale*

With potentially billions of dollars at stake, reliable and secure real-time drilling data is one of the most important requirements for oil and gas drillers today.

T

oday, oil and gas exploration companies are in the situation where easy exploration is no longer possible. Now they must not only use more sophisticated technologies to take advantage of business intelligence and identify profit opportunities upstream, but they must also employ cost-effective ways to send that information to decision-makers. Using proprietary software and custom solutions with every engagement is no longer economically feasible, and so there is a need to move towards an industry specification that enables interoperability, security, performance, reliability, cost and affordability. While workers pull oil from the ground upstream, everyone within the organisation must be in sync to achieve business objectives from the ground all the way to the fuel pump.

In order to improve security and efficiency, drillers are seeking a secure connection to speed up application deployment by cutting out manual processes and unrelated management systems. One challenge they face is how to decrease complexity and costs while ensuring an integrated network that allows for secure data transfer.

These days companies need information quickly and efficiently before, during and after drilling operations. They also need to move the massive amount of data collected securely between all disparate systems. By ensuring decision-makers will be able to collect, analyse and put data in the proper context, companies can make accurate and timely decisions.

20 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

The ‘Night Dragon’ attacks that started in November 2009 demonstrate the need for more security. Hackers were able to access oil companies’ systems and steal information including financial documents related to oil and gas field exploration and bid negotiations, in addition to operational details on oil and gas field production Supervisory Control and Data Acquisition (SCADA) systems. That attack emphasised that security must be strong from the field all the way through the enterprise.

Big gains from real-time drilling data Drilling for oil or gas is a science, and with an incredible amount of money on the line, people need to make the right decisions in real time.

Most wells today are directional, which does not mean that they are straight up and down - instead, they hit a specific spot and then level from an angle at great distances. To reach this level, a rig must drill the hole while a measurement-while-drilling (MWD) tool provides directional information and an electronic data recorder (EDR) monitors the operation.

The MWD tool is an electronic down-hole tool capable of gathering telemetric and formation data at the point of contact and then transmitting it up the hole during drilling operations. This allows the rig to steer in real time. The EDR system consists of sensors, data acquisitions, computers and a database. It acquires data from

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Software

ray, compass direction, drill bit direction, borehole pressure, temperature, vibration, shock, torque and so forth.

WITS allows the transfer of this well site drilling data from one computer system to another through the use of a fixed format ASCII data stream consisting of discrete data records. Each data record type generates independently of the others. Each type also has a unique trigger variable and sampling interval.

The communication goes two ways because WITS incorporates the ability for a remote computer system to send instructions to the sending system to set or change certain parameters, including the type of data transmitted and the interval for transmission.

WITS drivers therefore need to support bidirectional communications where the driver can read from or write to the WITS data stream through OPC or any of the other client interfaces available on the SCADA platform.

In addition, there is another specification making the rounds Wellsite Information Transfer Standard Markup Language (WITSML).

WITSML is an industry initiative to provide open, non-proprietary, standard interfaces that allow instrumentation and software to work together to monitor and manage wells, completions and work overs.

While the goal of WITS and WITSML is essentially the same, the technology is not. WITS uses a binary file format for transferring well site drilling data. WITSML is web based and built on XML technology, which is platform and language independent.

Example cases

a large number of rig sensors, displays it to the rig crew and other parties, and then stores it in a database.

From the beginning, it is a challenge to get the MWD data and transmit it securely to the EDR system so the crew can easily see the real-time telemetric and formation data and make steering and drilling decisions. That is where the Wellsite Information Transfer Specification (WITS) comes into play. This protocol provides a simple link that allows the MWD systems to transmit data to the EDR system in real time.

The WITS protocol has multiple communication levels. The Level 0 specification provides a real-time connectivity standard for sharing information between MWD down-hole drilling devices and systems that support the WITS protocol. Taking advantage of this data in a SCADA system involves developing a suite of WITS Level 0 communication drivers that provide the ability to easily transfer down-hole drilling measurements to HMI, SCADA and OPC Client applications.

Bidirectional communication The MWD tool gathers drilling-related measurements down-hole and then digitally transmits the data to the surface using mud pulser telemetry or other advanced technologies, such as electromagnetic frequency communications or a wired drill pipe. MWD systems take several measurements vital to drilling operations, such as gamma

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Oil giant Chevron uses the latest digital technologies in its mission control centres to focus on utilising real-time data to make collaborative decisions in drilling operations, or in managing wells and imaging reservoirs, for higher production yields. The company’s goal is simple: they want to improve performance and increase productivity and profitability. By using such technologies at these mission control centres, the company thinks it will save $1 billion a year.

Proprietary systems that operate in the field have gone the way of the typewriter. With separate companies often working together in a drilling operation, the only previous consistency in their communication systems was there was no consistency. In the effort to determine how to transfer data with each other, the partners were always starting from scratch. It took time to create new software, test it and then debug it before the two firms’ data collection and analysis systems could communicate. It not only wasted time, but it was also expensive and typically lost data.

With WITS, drillers are able to quickly connect, communicate and collect data to make real-time decisions that can save time and money. They need a flexible and scalable solution to connect, manage, monitor and control devices and software. They also need to manage communications through a robust platform that supports open standards such as OPC, DDE and ODBC and proprietary communication interfaces, protocols and APIs. Supporting these open standards and proprietary communications improves operations and enables better decision-making through all levels of the organisation.

Imagine the communications challenges for a project like Exxon Mobil’s complex Sakhalin-1 Project in the Arctic. Exxon Neftegas Limited (ENL), a subsidiary of Exxon Mobil Corp, is the operator of the Sakhalin-1 Project located offshore from Sakhalin Island. Partners include the Japanese company Sakhalin Oil and Gas Development

JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

Software

Co Ltd; subsidiaries of Russian state-owned oil company Rosneft, RN-Astra and Sakhalinmorneftegas-Shelf; and Indian state-owned oil company ONGC Videsh Ltd. The first phase of Sakhalin-1 consisted of an onshore drilling rig with extended reach wells and an offshore drilling and production platform. At 70 m tall, the Chayvo land-based drilling rig named Yastreb is the largest and most powerful land rig in the industry, designed to withstand earthquakes and severe Arctic temperatures.

Yastreb drilled down and then horizontally under the sea floor for more than seven miles, making this extended-reach well one of the longest in the world. Extended-reach wells reduce development costs and minimise marine impacts by avoiding the need for additional offshore structures.

Everyone on the same page While the Sakhalin-1 Project may be extreme, it just goes to show how important communications are in all aspects of the operation.

With major companies working on the same project, it is vital to get the data out to the partners. One of the major challenges faced by exploration and production companies is receiving multiple types of information every day from different directions and sources. It is not always easy to retrieve this data on demand, and in some cases, it never reaches the recipient because it is misfiled or lost.

With the common consortia of oil and gas companies working at drilling sites today, each joint venture partner demands timely

22 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

THE NEED REMAINS SIMPLE: PULL TIMELY AND ACCURATE DATA FROM THE SITE, PUT IT INTO CONTEXT AND THEN GET IT IN THE RIGHT HANDS.

information on progress so operational and financial decisions can be made. Time is money. The operating company needs to have a reliable, efficient and consistent way to distribute information. This often puts pressure on operating company staff at critical times.

Instead of searching for the information, operators would rather be analysing the data.

It all starts and ends with the product energy companies are pulling out of the ground. The need remains simple: pull timely and accurate data from the site, put it into context and then get it in the right hands. This need is simple for sure, but the complexity of the tools is becoming greater. The end result means more energy, more product and more profit - all in real time. *Gregory Hale is the editor/founder of Industrial Safety and Security Source (ISSSource.com).

Automation Direct Pty Ltd www.automationdirect.com.au

www.ProcessOnline.com.au

NEW PRODUCTS

GAS AND LIQUID ULTRASONIC FLOWMETERS Accuracy, line size breadth and flexibility make the Daniel JuniorSonic one-path (3411) or twopath (3412), and SeniorSonic four-path (3414) gas ultrasonic meters suitable for a number of flow measurement applications. In addition, the four-path (3814) liquid ultrasonic meter expands on the functionality and performance of its predecessor, the 3804 liquid ultrasonic meter, to offer improved reliability for custody transfer applications.

With faster flow sampling rates, the improved electronics platform significantly increases the data set used to calculate average velocity, allowing rapid recognition of changing flow dynamics. Users will have access to high-volume data capture as well as detailed flow parameters, including pressure, temperature and gas composition, allowing the meter to act as a redundant flow computer.

Improved calculations for auditing or invoice resolution are enabled by the electronics’ fast delivery of key data from the meter’s audit trail. The audit trail complies with American Petroleum Institute Standard 21.1 and is supported by a standard 128 MB non-volatile memory.

The meters’ electronics feature a compact circuit board for increased reliability and maintainability, simplifying field removal and reinstallation, and can be retrofitted in Daniel legacy ultrasonic meters.

The electronics supports remote access as well as true 100BaseT Fast Ethernet connectivity to facilitate enterprise-wide communication and integration.

Each Daniel gas ultrasonic meter is supplied with rugged T-20 Series transducers that are engineered for wet, rich and/or dirty gas applications. The transducers facilitate troubleshooting by enabling operators to quickly detect and isolate problems, preventing unnecessary depressurisation of the meter.

Emerson Process Management www.ap.emersonprocess.com

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JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

NEW PRODUCTS

HMI DEVELOPMENT TOOLS Plant operations are best positioned to maintain automated processes via effective HMIs. Common look and feel of visualisation from local machine control up to the supervisory layer is most important for consistent system useability. The Simatic TIA Portal makes it possible to see an entire automation system from one platform. Totally integrated automation (TIA) maximises both engineering efficiency and control system transparency.

WinCC V13 is the engineering system in the TIA Portal, allowing good visualisation for all current Simatic HMI panels and

MOBILE CRUSHING PLANT

PC systems. Simatic WinCC V13 allows visualisation of HMI

The Metso Lokotrack LT1213S mobile impactor with onboard screen

run-time stations for both single user and multi-user systems.

is more productive and economical than previous models, and is

WinCC V13 not only provides good interplay between Step 7

equally suited to the processing of both new aggregates and recy-

V13 and S7-1200 and S7-1500 control systems, but also with

cled material. It can be configured with the screen as a closed loop

S7 controllers configured with Step 7 Prof 2010. The V13 ‘device

machine or the return conveyor can be slewed to build a stockpile.

proxy’ allows the integration of newer Simatic HMI options,

The screen is also readily detached, allowing the LT1213S to be used

regardless of the S7 controller configuration software used.

as a straight crusher.

For additional system diagnostics in WinCC V13, the PLC

A number of elements have been combined to deliver a 15%

code viewer enables the status of controller function blocks

reduction in fuel consumption when compared to previous models,

(S7-1200/1500) to be

including a direct belt drive to the crusher; optimisation of the engine

represented in the su-

speed via a newly designed and more efficient hydraulic system; use

pervisory layer. This

of an independent demand-driven hydraulic drive fan; and an idle

means system mal-

mode, which is activated when the feeder and crusher are empty and

functions can be easily

deactivated when material is placed in the feeder.

traced by operational

The most significant improvement is in screening capacity: gener-

staff. Such supervisory

ally the limiting factor in a combined crushing/screening operation.

systems can also be

The machine’s 3600 x 1600 mm dual slope screen is 40% larger

made highly available

than the previous model and achieves a 20-30% greater throughput

via primary/standby

of finished product.

servers with the redundancy option.

The new machine is designed to set up, change configuration and pack up without the need for any assistive equipment such as

Wide-screen support across the entire HMI range with

a crane, or for heavy manual handling. The radial side conveyor can

WinCC V13 provides up to 40% more display area compared

be slewed from the side of the machine to the stockpiling position

to traditional devices with 4:3 aspect ratio.

in under two minutes without assistance.

Siemens Ltd

Metso Minerals (Australia) Limited

www.siemens.com.au

www.metso.com

24 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

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NEW PRODUCTS

THERMAL CAMERAS Designed to help streamline thermal inspections for intensive electrical, mechanical and utility predictive-maintenance programs, the updated FLIR T-Series cameras include the T420 and T440 with 320x240 thermal resolution, and the T620 and T640, both of which offer the company’s best handheld thermal detector resolution at 640x480 (307,200) pixels. Every model includes the company’s MSX enhancement that highlights thermal images with key visible details in real time for easier recognition.

The company’s rotating optical block lets users easily aim overhead, under equipment and from other tough angles while keeping the large LCD in comfortable view. T-Series cameras also include Auto-Orientation which automatically keeps on-screen temperature measurement data upright for easier viewing whether the camera is framed for landscape or portrait imaging.

The T620 and T640 feature a capacitive touch screen for navigation, and the keypad buttons on all of the latest models have been optimised to make it easier to activate the interface with gloves on.

T-Series cameras also include fast Wi-Fi communication that connects cameras to Apple and Android devices. Using the free FLIR Tools Mobile app, thermographers can import, analyse and share images and reports directly from the inspection site. In addition, the app can stream live video to nearby devices for safer monitoring. Wireless connectivity also extends to FLIR MeterLink test instruments that can send readings directly to T-Series cameras via Bluetooth, automatically embedding electrical load and other critical data into radiometric thermal images as they’re captured.

FLIR Systems Australia Pty Ltd www.flir.com.au

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JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

NEW PRODUCTS

REMOTE TERMINAL UNITS Moxa’s ioPAC 5542 remote terminal units (RTUs) are hardy, compact, metalencased all-in-one controllers that combine a GPRS/HSPA cellular modem, fully featured I/O terminals and a data logger in a single device.

The ioPAC 5542 is an RTU that supports standalone data logging expandable up to 32 GB. The ioPAC 5542 comes with Moxa’s Active OPC Server software, which confers the power of push communications, from edge to core, giving benefits that include reductions in data transmissions, lower hardware costs, and lower deployment and maintenance costs. The ioPAC 5542 RTUs additionally feature high sampling rates, a prerecorded event buffer, millisecond scale timestamps and a choice of C/C++ or IEC 61131-3 programming platforms.

Designed to work reliably in harsh industrial environments, ioPAC 5542 RTUs feature railway-grade ESD and surge protection, wide tolerance for temperatures from -40 to 75°C (-30 to 75°C for HSPA models), and are UL/cUL Class 1 Division 2 and ATEX Zone 2 certified. For network redundancy and communications security, ioPAC 5542 RTUs come with two 10/100 Mbps Ethernet ports that may be trunked into a single uplink, as well as two software-selectable 3-in-1 serial ports. ioPAC 5542 RTUs provide benefits beyond high-performance RTU roles; they are suitable for a wide variety of industrial applications, including pipeline monitoring for water, oil, and gas; pump- and lift-station monitoring; environmental monitoring; and security surveillance.

Madison Technologies www.madisontech.com

CODE READER The main strength of the LECTOR620 OCR is claimed to be its reading of printed plain text and simultaneous identification of all conventional 1D and 2D codes. The camera-based code reader offers simple commissioning and suitability for differing types of font, which can also be taught-in during running machine operation.

The stationary and dynamic detection of numbers, letters, symbols and codes is highly reliable, even with critical print quality, due to intelligent decoding algorithms. The most frequent areas of use for the LECTOR620 OCR include reading use-by dates and batch numbers on food and pharmaceutical packages, identifying data matrix codes in particular, and monitoring the feeding-in of packaging and blanks to packaging machines.

With integrated red and blue illumination, the LECTOR620 OCR ensures optimum lighting of the reading field at all times, regardless of the contrast. The code reader permits the detection of plain text letters, symbols and numbers at distances of between 30 and 300 mm. This is possible both while stationary and at speeds of up to 4 m/s. The integrated text-finder ensures that plain text can be reliably read or compared even with printing tolerances on the packaging.

The teach-in of texts takes place in teach mode. No special software is required for teaching-in letters, symbols and numbers because the code reader also has an integrated web server. In addition, fonts can be rapidly copied from one device to as many other devices as required via PC or MicroSD card.

Sick Pty Ltd www.sick.com.au

26 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

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WHEN YOU NEED A Quote ? An Answer? An Update?

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Quick and easy access to products and services in Australia. Emerson continues to invest in resources and capabilities to support customers in Australia. Newly launched Emerson Process Management Australia Online Store, together with Live Chat and Order Status Tracking Program, simplifies the purchasing experience for customers, enabling them to directly place orders online for selected Rosemount products and spare parts. The online store is one of many recent programs to equip Australian customers with the insight and capabilities to operate their plants at their full potential.

Customers may access the store 24 hours a day, 7 days a week at: store.rosemount.com/AUonline

The Emerson logo is a trademark and a service mark of Emerson Electric Co. Š 2014 Emerson Electric Co.

O

CASE STUDY

Olympus helps keep ‘Frosty’ on track for Bathurst success When Mark ‘Frosty’ Winterbottom joyously lifted the winner’s trophy for the 2013 Bathurst 1000 race, it was a tribute to the whole Ford Performance Racing team. Among those celebrating behind the scenes were the engine technicians who had used an Olympus videoscope before the race to visually inspect the inside of the engine of his Pepsi Max-sponsored V8 Supercar to detect cracks, scoring, material transfer or other flaws that could have potentially led to a catastrophic engine failure during the race.

Olympus has partnered with Ford Performance Racing (FPR) since 2007 to provide the team with the latest technology to ensure their cars are tuned for success. “The level of support in terms of servicing the scopes we have, and upgrading equipment to the latest model, has been sensational,” according to FPR’s chief engine builder, Ashley Campbell.

FPR competes all over Australia in the V8 Supercar Challenge race series, and the win on the Mount Panorama circuit was the team’s first victory in the nation’s premier motor racing event.

A videoscope is an inspection instrument that consists of a s m a l l c a m e ra mounted on a length of cable. The camera can be controlled remotely by an operator while it is inserted in the cavity to be inspected.

T h e g ove r n i n g body for V8 Supercar ra c i n g s t i p u l a t e s t h e p e r fo r m a n c e characteristics that all vehicles must comply with in order to participate in a race or series. This means that the size and weight of each frontengined, rear-wheel drive vehicle is essentially the same. The only differentiation is in the tuning and performance of the engine.

“To us, the videoscope is absolutely essential and we are able to eliminate major failures because we are able to know the condition and viability of an engine throughout its life,” stated Campbell. The latest model supplied to FPR is lighter, easier to use and more conducive to how the team operates in the ‘pressure cooker environment’ on the Saturday night of a race meeting.

The highly skilled FPR engine technicians spend the time between races stripping down and rebuilding race car engines in preparation for the next series. It takes between six and 10 weeks to build an engine from scratch and about two weeks to strip down and rebuild an existing engine.

Once an engine is ready, it is run on a fully automated dynamometer which allows the technicians to check ring seals, pistons and bore seals. The engine is run under optimum conditions for oil temperature and pressure. It is also connected to a computer ‘mapping’ program that maps the generic tuning to match all the idiosyncrasies of a particular powerplant.

28 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

After the engine is removed from the dynamometer, it is inspected using the Olympus videoscope to see if there are any signs of wear or damage or if unplanned events have occurred in the engine.

The Olympus videoscope has enabled the team to catch many potential failures before they cause problems while racing.

According to Campbell, technicians can detect indications of markings in the cylinder wall or evidence of transfer of material from the piston to the cylinder wall. By removing the engine and stripping it down to its components, the engine technicians are able to limit damage to a single part or component before it impacts the rest of the engine.

FPR technicians plan for an engine to be in a car for the full race meeting. However, the team always has a spare engine in the support truck. Except for the exhaust manifold and pipes, the spare unit is ready to go with all ancillary components and plumbing already attached.

During an engine change, everything from the harmonic balancer at the front of the unit to the flywheel with the clutch attached is removed and replaced. When a new engine is placed in the car, the first two things connected are the oil and water.

“The oil is kept heated and the water is at 65° prior to starting the engine,” said Campbell. “This is to eliminate cold start wear because when engine components are cold, they are not at their operating size.”

Olympus is willing to work with customers to adapt or modify instruments to meet their needs. “We have worked with FPR for several years now and have upgraded their equipment to the latest, lightweight model,” said Mark Wheatley, sales specialist at Olympus. “With the new untethered videoscope, the race technicians can quickly inspect an engine in the pit straight if necessary, rather than bring it into a workshop.”

Campbell concluded that his team is looking forward to trialling new high-speed camera systems that Olympus has been discussing with FPR. “We will be able to view and record the actions of most parts of our engines and see what might be the actual event that causes an engine failure, rather than just the aftermath,” he said.

A longer and more detailed version of this article can be read online at http://www.processonline.com.au/case_studies/68189Videoscope-helps-Frosty-39-s-success-at-Bathurst Olympus Australia Pty Ltd www.olympusaustralia.com.au

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NEW PRODUCTS

REFINING AND PETROCHEMICAL PLANNING Honeywell has announced a major enhancement to its Refinery and Petrochemical Modeling System (RPMS) that will improve model building and maintenance, case management and optimisation to help plants maximise profitability. The updated release, RPMS 500, incorporates analytics software that is based on the company’s Intuition process management to better apply planning results.

RPMS also helps refining and petrochemical firms assess their long-term investment options and understand the critical differences in potential yield and value of various feedstocks, as well as determining the best operating conditions over the planning horizon.

RPMS Release 500 makes it simpler to build and maintain refinery planning models and generate and review production plans. That helps provide information to help operators make the best production decisions. It also includes a web-based tool that makes it easier for the broader organisation to access and analyse the information.

Key features with the RPMS 500 release include support for Windows 7/8 64-bit platforms, as well as tools to simplify migration to the current software version. Other enhancements provide improved case management, a new graphical user interface, HTML-based reporting and improved optimisation capabilities.

Effective planning is critical to help today’s process industries increase profitability. RPMS helps enable development and analysis of advanced mathematical programming models, utilising linear programming (LP) optimisation to answer key business questions related to raw material purchases, product specifications, plant operation and distribution and logistics.

Honeywell Limited www.honeywell.com.au

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JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

Ari vAlves…

GermAn reliAbility protectinG your plAnt.

NEW PRODUCTS

GSM/3G MONITOR AND CONTROL NODE The ZigSense model ZS3G-SMS is an out-of-thebox monitor and control node utilising standard GSM/3G cellular networks as its communications

ARI ‘SAFE’ Safety and Relief Valves for Oil & Gas and Industrial applications involving steam, hot water, compressed air, gases and thermal oil. Highest quality components and smart design guarantees reliable long life and fast, easy servicing.

In cast iron, nodular iron, cast steel & stainless steel.

infrastructure to exchange SMS messages.

By sending SMS commands to the ZS3G-SMS cellular node, authorised users can remotely monitor and control up to four digital inputs and four digital outputs wired to a wide range of industrial equipment, remote irrigation systems, motors, pumps, generators, fans, lighting systems and PLCs. Using a standard mobile or smart phone, authorised users enter commands selected from a list of preprogrammed SMS messages. These commands are sent to cellular phone numbers predefined by the user.

For every command sent by the user, the ZS3G-SMS cellular node returns an SMS acknowledgement message advising the sender whether the command was successfully accomplished.

To maintain safety and security, the ZS3G-SMS cellular node constantly checks that the message was sent by an authorised cellular phone number and that the SMS message matches the syntax programmed in the cellular node’s non-volatile memory. Erroneous SMS message syntax or commands sent by unauthorised users will be rejected. Rejection messages are sent to the sender and to the administrator.

Conlab Pty Ltd www.conlab.com.au

PRESSURE CALIBRATORS Suitable for gas custody transfer applications, the Fluke 721 preci-

ARI sAfety & RelIef vAlves

sion pressure calibrator has dual

DIN and ASME VIII UV coded Semi and Full nozzle models.

Flanged & Threaded connections.

isolated pressure sensors, allowing users to take simultaneous static and differential pressure measurements with a single tool.

Large range of safety and process vaLves in stock for immediate deLivery. austraLian agent & stockist

An optional RTD probe makes for a complete solution for testing flow computers and instruments used in gas flow measurement.

To eliminate hand pumping, the 719Pro includes a full functioning loop calibrator that sources, simulates and measures mA signals, making it a suitable test tool for calibrating high-accuracy transmitters, pressure switches and pressure gauges. Notable improvements include expanding the pressure measurement range of the 100 psi model up to 150 psi and the addition of a 300 psi range. The 719Pro adds a backlit display and precision temperature measurement with the addition of an RTD probe accessory.

Tel: (03) 9699 7355 www.pressureandsafetysystems.com.au

Fluke Australia Pty Ltd www.fluke.com.au

9193p&ss-Wnipt1

30 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

www.ProcessOnline.com.au

NEW PRODUCTS

REDUCED FOOTPRINT PROCESS PUMP The Bran+Luebbe Novaplex Vector process pump from SPX offers a reduced footprint size, reduced weight, increased efficiency and improved reliability features that will be welcomed by companies operating offshore platforms and FPSO units (floating production, storage and offloading).

The Novaplex Vector design arranges the pump heads in three dimensions to reduce the footprint and the overall weight of the pump. As a result of reducing the number of crankshaft bearings from six to two and by generally simplifying assembly, the unit is designed for increased reliability and ease of maintenance. Maintenance engineers should note that the Novaplex Vector only requires the disassembly of the drive to gain access to the gears.

Equipped with robust Bran+Luebbe diaphragm pump heads, the pumps can be installed in potentially hazardous atmospheres and are suitable for handling hazardous fluids. Typical applications include methanol and polymer injection, hydrocarbon transfer in oil and gas production, LDPE production, reactor feed in the chemical industry, and areas such as autoclave feed in the mining industry.

As an option, the Novaplex Vector pump can be equipped with a Novalink-CSM 2 continuous pump monitoring system, which can be incorporated into an asset management system or used as a standalone solution. The software enables vital advance detection of possible pump failure, allowing planned maintenance to be scheduled and resulting in optimised uptime and protecting production capacity.

SPX Flow Technology Australia Pty Ltd www.spx.com.au

POWER OUTAGE SOLUTION Schneider Electric has launched its Power Outage Insight (POI) solution in the Australian market. The crisis prevention and recovery system maximises continuous access to safe electricity across critical power applications. The solution is tailored for a number of sectors where uninterrupted power supply is highly critical including data centres, mining, oil and gas, and health care.

As an integrated solution with no additional software required, Schneider Electric’s POI monitors low-voltage electrical distribution systems and schedules predictive maintenance for minimising unexpected downtime through its intelligent web-based interfaces.

In case of a power failure, the software performs real-time diagnostics to quickly identify the source of the problem and provides concise and easy-to-follow power restoration instructions.

Additionally, the POI solution provides a wireless breaker closing remote control device that allows users to close breakers from a safe distance.

The POI solution is cost effective and easy to install in both greenfield and existing sites for immediate improvement in power reliability. Its embedded database provides traceability of repairs, maintenance and changes to device settings and layout for ease of long-term management.

Schneider Electric Power Business www.schneider-electric.com.au

www.ProcessOnline.com.au

JULY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

NEW PRODUCTS

PROJECT EXECUTION SERVICES Honeywell Process Solutions has launched its LEAP project services (Lean Automation of Automation Projects) to help manufacturers in the processing industries get their plants up and running faster and at lower cost.

LEAP combines Honeywell Process Solutions proprietary hardware and software, virtualisation and cloud engineering to give users greater scheduling flexibility while reducing risk and total automation costs by up to 30%. Honeywell claims that multiple industries can benefit from an estimated 80% reduction in costs related from unnecessary rework, and that these features can also help reduce avoidable schedule delays by up to 90%.

According to Honeywell, LEAP represents a major departure from the way plants are typically designed and built by using parallel workflows to keep automation systems off critical Š iStockphoto.com/vm

implementation paths. Traditionally, sequential workflows call for the automation and controls to be implemented during a specified time frame before the rest of the plant can be completed.

This approach poses challenges such as managing changes, which can affect all subsequent steps of the implementation and threaten project schedules and budgets.

LEAP creates separate streams of work for the physical and functional aspects of project design. This approach allows project engineering to take place from anywhere in the world and removes workflow dependencies to allow core project tasks to start much earlier in the process. It also dramatically minimises the cost and volume of rework typically associated with automation projects.

Honeywell Limited www.honeywell.com.au

Sensor Monitoring Services

OPC SERVER FOR FOXBORO I/A

Industrial Control ZigSense cloud controller is an

Energy Metering

MatrikonOPC has released

Refrigeration

Tank & Silo Level

an enhanced MatrikonOPC

Gas Monitoring

Server for Foxboro I/A,

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.

Pollution Horticulture Aquaculture

which includes support for Foxboro I/A Series systems version 8.8. The OPC server securely facilitates communication between OPCenabled client software, such as HMIs, historians and reporting software, and Foxboro I/A devices.

Recently, Invensys announced the deprecation of FoxAPI beginning in version 8.8 of Foxboro I/A. This update allows users of Foxboro I/A 8.8 and above to continue to use OPC-based communication by leveraging the AIM API. By porting their products to the Invensys preferred APIs, Matrikon OPC supports I/A Series systems version 8.8 and the migration of those systems to Windows 7 and Microsoft Server 2008 R2 operating systems.

Key features of the OPC server include: support for FoxAPI, Object Manager and AIM API; integrated OPC security; real-time (DA) and historical (HDA) OPC data access; and

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

32 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

built-in alias configuration.

MatrikonOPC www.matrikonopc.com

www.ProcessOnline.com.au

NEW PRODUCTS

WIRELESS ACCESS POINT To make accessing critical production data easier within the manufacturing enterprise, Rockwell Automation is

OUTDOOR M12 CABLING

launching the Allen-Bradley Stratix

Phoenix Contact has extended its range of

5100 wireless access point (WAP)

M12 connectors for outdoor use with cabling

featuring a workgroup bridge.

for CANopen and DeviceNet applications.

Unlike typical wireless clients that

The moulded M12 connectors use high-

only connect a single IP address,

quality materials such as V4A stainless steel

the Stratix 5100 WAP enables engineers to

(1.4404), polypropylene plastics, and a special

connect up to 19 IP addresses simultaneously - helping reduce design time

sealing concept. This design enables use

when integrating machines and equipment into the industrial control network.

in temperatures up to 105°C and ensures

The Stratix 5100 WAP is suitable for industrial networks needing secure

good resistance to high-pressure cleaning

and reliable wireless connectivity. Enterprise-class silicon and optimised radios

and sunlight (UV). The connectors are there-

deliver a robust mobility experience that includes 802.11a/b/g/n with 3-by-4

fore designed for use outdoors under harsh

multiple-input multiple-output (MIMO) technology and three spatial streams.

conditions.

The Stratix 5100 WAP uses Cisco IOS, providing world-class performance

The range includes fully shielded connec-

and configuration options. In addition, the Stratix 5100 WAP provides integra-

tors in straight five-position pin or socket

tion to the Rockwell Automation Integrated Architecture system with detailed

design with an FRNC DeviceNet cable. The

network diagnostic information. The Stratix 5100 WAP complements the Allen-

cable sets are available in lengths of 2.5 or

Bradley ControlLogix EtherNet/IP communication modules and full portfolio

10 m; customer-specific lengths are available

of Stratix switches from Rockwell Automation.

on request.

Rockwell Automation Australia

Phoenix Contact Pty Ltd

www.rockwellautomation.com.au

www.phoenixcontact.com.au

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

• Modbus RTU communications.

• Ethernet Modbus TCP and Profibus gateways.

• Compact DIN-Rail packaging with integrated Bus connector.

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

www.proconel.com www.ProcessOnline.com.au

JULY 2014 - 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 ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au

CUSTOMISE OR COMPROMISE

Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor Janette Woodhouse

I

n challenging economic times, we can do well to stop and reflect on some of the past methods our industry has used to solve engineering challenges techniques that now seem simple yet enabled many systems to be automated and industrial plants to operate reliably and efficiently for many years. By evaluating these past techniques, we can see if they are still relevant in today’s ever-changing environment.

One of my first roles as a young electronics designer was to develop equipment for an emergency shutdown system. This was to be installed in a major water treatment plant. The design incorporated relay logic and level detection, and had to remain energised for the life of the plant. No off-the-shelf product was then available so it was my job to make it happen. Fortunately, all went as planned and it is still in operation 30 years later.

The customised design, in this case, was a necessity. Sometimes it can also be a desirable way to achieve more than just the initial goal.

Providing clients with ‘customised’ solutions for their process control and industrial automation requirements has many benefits. Back when customer loyalty was more than just two consecutive orders, there was a real desire to build on customer relationships and foster long-term partnerships with suppliers.

There can be no better way of suppliers and customers forming closer ties than having the opportunity to design dedicated equipment that forms an integral part of their system.

These close customer-supplier relationships help to facilitate better engineering outcomes and foster long-term partnerships.

Over the past three decades, I have seen the gradual decline in suppliers offering tailored product solutions. One size

Publisher

fits all seems now to be the norm. Has it just become too hard, or are we getting lazy? There will always be a place for off-the-shelf solutions, but if we spend some time evaluating the real benefits of a more tailored approach we also end up with a far better understanding of the total system.

I have always approached functional design with the goal of simplifying each process to its basic core functions and then adding in only those features that contributed to safety, efficiency and longevity. Applying this approach to customised products enables us to develop easily manufacturable sub-units that together implement the desired functions. One of my goals has always been to reduce the possibility of electrical interconnection wiring faults between subsystems. This can be realised if utilising a customised design, as a modular ‘plug-in’ or backplane’ approach is readily achievable reducing cabinet wiring to a minimum. Designed-in redundancy and forethought to expansion are both necessary factors that can be incorporated at the outset.

You can achieve the best outcomes without compromise if you stop and evaluate the possibilities that a tailored, fit-for-purpose solution can offer. If we all considered this approach, then just maybe we could stop more work from leaving our shores.

34 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2014

David Head has worked for Weidmüller Australia for the past 30 years. He is currently responsible for the company’s Electrical Connectivity and Application Specific Products.

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 - Mark Ryu ph: 0800 44 2529 mryu@westwick-farrow.com.au Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application.

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March 2014 total CAB audited circulation (Aust + NZ) 6,504 readers (76% personally requested)

Contact the editor

Printed and bound by Bluestar Print +61 2 9748 3411 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.

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